3D-Scanned Custom Earpiece Molds for Precise Ear Fit
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Solution Overview
Problem
Existing in-ear devices, such as earbuds and earplugs, often fail to fit properly due to a 'one size fits all' approach, leading to discomfort, loss, and potential hearing damage, while larger earmuffs are bulky and difficult to wear.
Innovation Solution
A method using an electronic device with a camera system to perform 3D scanning of a user's ear, associating a unique identifier with the scan, and utilizing a 3D printer to create a customized mold for a personalized earpiece with selected components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one size fits all earplugs are used, then manufacturing cost is reduced, but fitting precision deteriorates
Solution Approach 1:
The patent applies parameter changes by transitioning from fixed-size earplugs to customizable earplugs where size and shape parameters are adjusted based on individual ear scans. The system captures ear geometry data and uses it to generate customized earplug designs, allowing each user to receive earplugs with optimal dimensions for their specific ear canal shape and size.
2Manufacturing precision
If customized earpieces are made for each user, then fitting precision is improved, but device complexity increases
Solution Approach 1:
The patent applies copying by creating a digital replica or 3D model of the user's ear geometry through scanning. This digital copy is then used to generate the customized earpiece design without requiring physical molds or complex measurement procedures. The digital model serves as an accurate representation that simplifies the customization process.
Solution Approach 2:
The patent applies preliminary action by performing ear scanning and digital model creation before the actual earpiece manufacturing process. The user's ear geometry is captured and processed in advance, allowing the customization data to be ready when the manufacturing process begins, thereby streamlining the overall workflow.
3Ease of operation
If traditional earbuds are used, then ease of operation is maintained, but reliability deteriorates due to poor fit
Solution Approach 1:
The patent applies local quality by customizing specific regions of the earpiece to match the user's ear geometry. Rather than changing the entire earpiece design, the system adjusts local parameters such as the shape of the earplug portion, the angle of the stem, and the position of the speaker to optimize fit for that user's specific ear canal characteristics while maintaining the core functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables a precise fit and secure wearing experience, reducing the risk of loss and damage, and allowing customization of internal components for enhanced functionality.
Implementation Method 1
scanning an ear of the user with an electronic device that includes at least one camera system that configured to perform three dimensional mapping image scans
Implementation Method 2
forming, via a three-dimensional printer, a mold having an internal configuration corresponding to the one or more scans and the one or more earpiece parameters
Data Source
AI summary
A method for making a customized earpiece includes creating a unique identifier associated with a user, scanning an ear of the user with an electronic device that includes at least one camera system that configured to perform three dimensional mapping image scans, associating the unique identifier with one or more scans obtained via the electronic device, receiving, at a database, the one or more scans via transmission from the electronic device, receiving, at the database, one or more earpiece parameters via transmission from the electronic device, forming, via a three-dimensional printer, a mold having an internal configuration corresponding to the one or more scans and the one or more earpiece parameters. The mold can then be utilized to create a custom-fit earpiece that includes customized internal components and other features that match the earpiece parameters provided by the user. A system utilizing the above method is also included.