Non-occluding Earpiece Design via 3D Modeling and Rapid Prototyping
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Solution Overview
Problem
Existing methods for creating non-occluding earpieces are manual, time-consuming, and prone to variability, often resulting in material waste and risk of damaging the ear canal during grinding, leading to inconsistent products.
Innovation Solution
A computer-controlled method involving 3D modeling and rapid prototyping to create non-occluding earpieces with a tube bore, using techniques such as Boolean operations and control paths to define the canal shape and produce customized models efficiently, reducing material waste and ensuring precise fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual grinding method is used to create non-occluding earpiece, then the earpiece can be customized, but the manufacturing precision is poor and risk of damaging ear canal is high
Solution Approach 1:
The patent replaces manual mechanical grinding with computer-controlled automated shaping. The system uses digital 3D models and computer-controlled machinery to precisely define the canal area, eliminating manual intervention and achieving consistent, accurate results while maintaining customization capability through digital modeling.
Solution Approach 2:
The patent creates a complete 3D digital model of the ear canal and hearing aid components before manufacturing. The canal area is defined and verified in the digital model stage, allowing precision to be established beforehand and preventing errors during the actual manufacturing process.
2Adaptability or versatility
If manual grinding method is used to create non-occluding earpiece, then the earpiece can be customized, but the productivity is low and time consuming
Solution Approach 1:
The patent replaces time-consuming manual grinding operations with computer-controlled automated processes. The system can rapidly generate and manufacture customized earpieces by processing digital models through automated machinery, significantly increasing production speed while maintaining full customization capability.
Solution Approach 2:
The patent transforms the manufacturing process from manual to digital by changing the state of design parameters from physical measurements to digital 3D model data. This parameter transformation enables rapid modification and production of customized earpieces without the time constraints of manual methods.
3Adaptability or versatility
If manual grinding method is used to create non-occluding earpiece, then the earpiece can be customized, but the consistency of product quality is poor
Solution Approach 1:
The patent replaces manual operations with computer-controlled processes that execute identical algorithms for each customization case. This substitution ensures that the same precision and quality standards are applied consistently across all manufactured earpieces, eliminating variability introduced by different operators.
Solution Approach 2:
The patent creates accurate digital 3D copies of the user's ear canal geometry and uses these digital models as precise templates for manufacturing. Each earpiece is manufactured from its own customized digital model, ensuring consistent quality while maintaining individual customization.
4Adaptability or versatility
If manual grinding method is used to create non-occluding earpiece, then the earpiece can be customized, but the material waste is high
Solution Approach 1:
The patent defines the final canal area geometry in the digital 3D model before manufacturing begins. This preliminary digital definition allows for precise material removal planning, ensuring that only the necessary minimum amount of material is removed to achieve the non-occluding design, thereby reducing waste.
Solution Approach 2:
The patent uses computer-controlled precision machining to remove material exactly where and only to the extent needed based on the digital model. This precise control eliminates the excessive material removal and trial-and-error that occur with manual grinding, significantly reducing material waste.
Data Source
AI summary
The present invention provides a method for computer-controlled creation of non-occluding earpieces with tube bore. The non-occluding earpieces are created based on a three-dimensional computer model of at least part of the outer ear and at least part of the auditory canal. The said model is created by a laser scanner, in the ear scanner or by other means. The said three-dimensional computer model is virtually modified to create the non-occluding earpieces and the tube bore. Finally the physical non-occluding earpieces are manufactured using rapid prototyping equipment.