Hearing guides us in our daily lives, and it deserves to be protected from the risks of noise pollution, both in professional and personal settings.
3D technology also benefits the medical and health sectors.
Thanks to additive manufacturing techniques, hearing protection has taken a new turn: each ear device is unique, perfectly fitting the shape of the ear through 3D or traditional impression taking from the very start of the design process.
The advantages of custom hearing protection
The main benefits of 3D printing for hearing protection devices are numerous, but key points include:
High precision and unmatched quality: The materials used in 3D printing for hearing protection are often biocompatible and designed to be both durable and comfortable. Their superior quality contributes to the longevity and performance of custom-molded earplugs.
Custom products that fit every ear shape: Custom earplugs are made from the exact impression of the user’s ear, ensuring a perfect fit.
Reduced manufacturing time and customization costs: Thanks to this technology, it is possible to quickly produce custom items without the need for specific tools or molds, simplifying and speeding up the manufacturing process. The flexibility of 3D printing allows for easy adjustments to designs based on individual needs, reducing the costs associated with customization while maintaining high quality.
These advantages make custom hearing protection an ideal solution for anyone looking to protect their hearing in a comfortable and effective way, while meeting specific needs.
3D printing designs your earplugs
The process of manufacturing custom earplugs using 3D printing is an increasingly popular technique to provide personalized hearing protection tailored to each user’s specific needs. Here’s how the process works:
Ear impression: It all starts with taking an accurate impression of the patient’s ear. This can be done using traditional techniques (such as a silicone mold) or by 3D scanning the inside of the ear with a 3D scanner.
Digital modeling: The impression or scan is then converted into a digital 3D model using computer-aided design (CAD) software. This model faithfully reproduces the shape of the patient’s ear canal and outer ear.
Design customization: Once the 3D model is created, adjustments can be made to enhance comfort, sound isolation efficiency, or to add specific features (such as integrated acoustic filters). The final design is validated before moving on to the next step.
3D Printing: The digital file is then sent to a 3D printer. Technologies such as stereolithography (SLA) or selective laser sintering (SLS) allow for the creation of finely layered objects with great precision. The materials used are biocompatible resins, ensuring both comfort and durability.
Post-processing: After printing, the noise-canceling earplugs go through post-processing. This includes cleaning, polishing (smoothing the surfaces), and sometimes applying a coating to improve durability or aesthetics.
Quality control and adjustment: The printed earplugs are then subjected to quality control to ensure they meet specifications and fit the patient’s ear perfectly. Minor adjustments can be made if necessary to guarantee optimal comfort and effective protection.
Why choose custom hearing protection?
The benefits of 3D printing for hearing protection devices are numerous, but the key advantages are:
Comfort: Custom earplugs allow for extended wear without discomfort, making them ideal for those who need to wear them for long periods.
Ease of cleaning: By fitting perfectly, custom protection reduces the risk of harmful substances (like dust or water) entering the ear canal. Additionally, they are often easier to clean and maintain, which improves hygiene.
Durability: Made from high-quality materials, custom hearing protection is generally more durable than standard models. With proper care, they can last for several years.
Our subsidiary Earow, a merger of the Interson, Protac, and Auditech brands, brings its expertise to you and your company to provide the best hearing solution!
Employee health is a major concern in the workplace, and noise can sometimes negatively impact team well-being. 3D technologies specifically address the various needs of businesses: mitigating the risks of noise exposure at work and complying with legal requirements.
Industry
Tertiary: in offices
Use case: To filter harmful noises and isolate certain types of sounds in factories, on construction sites, and on production lines.
Technique: Custom-molded earplugs created from a traditional impression or with a 3D scanner. Made of acrylic, these devices ensure protection and a perfect fit for employees’ ears.
Use case: To significantly reduce ambient noise in offices, especially in open spaces or call centers.
Technique: A custom-molded ear protector made from a traditional impression or with a 3D scanner. Thanks to its silicone material, it offers flexibility and comfort, making it easy to put in and take out.
Hearing protection for individuals
The number one criterion for hearing aid users? Comfort!
With 40 years of experience, our subsidiary Earow Audition places this priority at the heart of its hearing device development. The concept of custom-fit is embedded in the manufacturing process of all our hearing product ranges: ear tips, hearing aid tips, custom hearing protection, earplugs…
Our quality guarantee:
Acoustic sealing
Optimized comfort
Maximum customization for a perfect fit to the curves of the ear canals.
Deaf and hard of hearing
To ensure a perfect fit, a digital impression of the ear canal is first taken directly by the hearing care professional.
Based on your ear measurements, we design the earmolds for hearing aids for the deaf and hard-of-hearing.
At Prodways, we also offer a wide range of hearing aid accessories for everyone, including the deaf and hard-of-hearing, such as transmitters, receivers, alarm clocks, mobile and landline telephones…
Custom hearing protection for music, such as the Pianissimo model and EarBack Music, is designed to offer linear sound attenuation, ideal for musicians. They reduce sound volume while preserving sound quality and fidelity, allowing performers to focus on their performance without auditory fatigue. These protectors ensure optimal comfort thanks to their personalized fit and offer various filtering and customization options to meet users’ specific needs.
Hunting and Shooting
Custom hearing protection for shooting and hunting, such as Sonorflex and Earsonic Shooting, provides specific sound attenuation to protect hearing while maintaining the perception of essential sounds, like ambient noise and communication.
They are designed for optimal comfort during prolonged wear, with filtering options adapted to different situations, ensuring effective protection against sudden and intense noises, such as gunshots.
Swimming
Custom hearing protection for water, such as Aquaflex and Earsonic Water, is specially designed to prevent water from entering the ear canal, while providing optimal comfort for aquatic activities. They are ideal for individuals prone to infections or irritation caused by water, such as swimmers or surfers. These custom protectors ensure a perfect seal and can be worn comfortably for extended periods.
Sleep
Custom hearing protection for sleep, such as Sleepsound, is designed to provide optimal isolation from surrounding noises, promoting restful sleep. Made from soft and comfortable materials, they fit perfectly to the shape of the ear for comfortable wear throughout the night. These earplugs are ideal for people sensitive to nighttime noises, ensuring deep, uninterrupted sleep.
Airplane
Custom hearing protection for communication, such as the IntraFlex Com and IntraCom models, is designed to enable clear communication while protecting hearing in noisy environments. They incorporate communication systems that filter out unwanted noise and amplify necessary sounds, making them ideal for professionals who need to communicate effectively in challenging conditions. These devices ensure optimal comfort thanks to their personalized fit.
The price of a custom-made earplug can vary depending on a number of factors, including the technology used to take the impression, the material chosen, the complexity of the customization and specific features (such as integrated acoustic filters). In general, the cost is between 100 and 300 euros per pair. For high-quality custom earplugs intended for professional or specific use (such as musicians, workers in noisy environments, or users seeking maximum protection), prices can be higher, especially if additional features are requested.
We recommend that you consult a specialist or hearing care professional for a precise quote based on your particular needs.
How do I choose the right hearing protection?
Choosing the right hearing protection depends on a number of factors, including the environment in which it will be used, the noise level, and personal comfort. Here are a few steps to help you make the right choice:
Assess the noise level: The noise level to which you are exposed is crucial in determining the type of protection you need. Very noisy environments (over 85 dB) require more effective protection. You can use a sound level meter to measure the noise level.
Determine the duration of exposure: If you’re exposed to noise for long periods, it’s important to choose protection that not only reduces noise effectively, but is also comfortable to wear for a long time.
Choose the type of protection :
Ear plugs: Small, discreet and practical. They can be made of foam, silicone or wax. Foam plugs are generally disposable, and are inserted by compressing the foam before allowing it to expand in the ear. Silicone and wax plugs are often reusable.
Noise-canceling headset: They are bulkier but offer better noise attenuation, especially at low frequencies. They are often preferred in industrial environments or for heavy-duty work.
Custom-molded plugs: These plugs are made from a mold of your ear and offer superior comfort. They are particularly recommended for musicians or for those who wear hearing protection regularly.
Check noise reduction (SNR): The noise reduction level, often expressed as SNR (Signal-to-Noise Ratio), is an indication of the protection’s effectiveness. For example, an SNR of 30 means that the protection can reduce the noise level by 30 dB. Choose protection with an SNR adapted to your environment.
Comfort and fit: Hearing protection should be comfortable to wear, especially if you have to wear it for long periods. Make sure it fits snugly without causing pain or excessive pressure. Sometimes it’s helpful to try on several types to find the one that suits you best.
Specific requirements: In some cases, you may need special features, such as hearing protection with acoustic filtration for musicians, to attenuate sound without distortion, or protection with integrated communication for environments where it’s important to keep in touch with colleagues.
In short, the choice of hearing protection depends on noise level, duration of exposure, comfort, and specific needs related to the environment or activity. Take the time to evaluate these criteria to find the most suitable protection, and contact our teams.
What are the most effective earplugs?
The most effective earplugs depend on a number of criteria, including the level of noise reduction required, comfort and specific use.
Here are a few types of earplugs known for their effectiveness:
Custom molded earplugs :
Efficiency: These are the most personalized and often the most comfortable earplugs, as they are molded exactly to the shape of your ear. They offer variable noise reduction depending on design, generally between 20 and 30 dB.
Benefits: Optimal comfort, reusable over the long term, and very suitable for musicians or regular users.
Disadvantages: Higher cost and need to be fitted by a hearing care professional.
Earplugs with acoustic filters :
Efficiency: They are designed to reduce overall volume while preserving sound quality, ideal for musicians or those wishing to reduce noise without losing clarity.
Benefits: Noise reduction without distortion, ideal for concerts, musicians or environments where communication is still necessary.
Disadvantages : Less effective for very loud noises than foam.
Foam earplugs :
Efficiency: These are among the most common and often the most effective noise reduction plugs. They generally offer a very good SNR, often around 33 dB, making them suitable for very noisy environments.
Benefits: They’re inexpensive, easy to use and disposable.
Disadvantages: Some may find them less comfortable, especially over a long period, and they need to be replaced regularly.
Silicone ear plugs :
Efficiency: These plugs offer good sound attenuation, often between 20 and 30 dB, with the advantage of being reusable.
Benefits: They are reusable, often more comfortable and malleable, suitable for prolonged use.
Disadvantages: They may be less effective than foam for very high noise levels, but remain very comfortable.
By how many decibels do earplugs reduce noise?
Earplugs can significantly reduce noise, but attenuation depends on the type of plug used. Here’s a general estimate of noise reduction depending on the type of earplug:
Foam earplugs: These offer some of the highest attenuation, with noise reduction typically between 30 and 33 dB. This makes them a popular choice for very noisy environments such as construction sites or concerts.
Silicone earplugs: These plugs, often reusable, offer medium attenuation, reducing noise by 20 to 30 dB depending on the model. They are suitable for moderately noisy environments and are more comfortable for prolonged use.
Custom-molded earplugs: These plugs, precisely adapted to the shape of the user’s ear, offer variable noise reduction, but generally around 20 to 30 dB. Their effectiveness can be comparable to that of foam plugs, but with greater comfort.
Acoustic filter earplugs: Designed to attenuate noise while maintaining good sound quality, these plugs reduce noise by 15to 25 dB. They are often used by musicians or at concerts to protect hearing while allowing music to be heard clearly.
Important note: The noise reduction level, often indicated by the SNR (Signal-to-Noise Ratio) or NRR (Noise Reduction Rating) on the packaging, is an average. Actual effectiveness may vary according to the way the plugs are inserted and adjusted in the ears, as well as the user’s individual characteristics.
In summary, earplugs can reduce noise by 15 to 33 dB, with foam plugs generally offering the greatest attenuation.
How to clean earplugs?
Cleaning earplugs is important to ensure their effectiveness and durability, while preventing ear infections. Here’s how to clean different types of earplugs:
Custom-molded earplugs
These earplugs require special care because of their cost and customization:
Washing with warm water and soap: As with silicone plugs, use warm water and mild soap. Avoid harsh chemicals that could damage the material.
Using a soft brush: You can use a small, soft brush to clean hard-to-reach areas.
Disinfection: For a more thorough cleaning, you can occasionally soak them in a solution of 70% isopropyl alcohol for a few minutes, then rinse with lukewarm water.
Drying: Air-dry before storing in the case.
General advice :
Do not use: Do not use harsh chemicals or pure alcohol to clean ear plugs, unless otherwise specified.
Replacement: Even reusable caps should be replaced when they show signs of wear or damage.
Storage: Store earplugs in a clean, dry case when not in use.
By following these cleaning tips, you can extend the life of your earplugs while ensuring their effectiveness and your hearing hygiene.
What materials are used to make noise plugs?
Earplugs are made from several types of material, each with its own characteristics in terms of comfort, effectiveness and use. Here are the most commonly used materials:
1. Foam
Description: Foam is a flexible, compressible material, usually made of polyurethane or PVC.
Application: This type of plug is often disposable, designed to be inserted into the ear canal by compressing and then expanding to fit the shape of the ear.
Advantages: Good noise attenuation, often the most effective at blocking out loud noises.
Disadvantages: Can become uncomfortable after prolonged use and must be replaced frequently.
2. Silicone
Description: Silicone is a flexible, durable material used to make reusable closures.
Application: Silicone plugs are often molded or shaped to fit comfortably in the ear. Some models are made of malleable silicone, which the user can shape to suit his or her needs.
Advantages: Comfortable for prolonged use, easy to clean and reusable.
Disadvantages: Less effective at attenuating extremely loud noises than foam.
3. Wax
Description: Wax, often mixed with cotton or other fibers, is used to make moldable ear plugs.
Application: Wax plugs are generally used to block out noise while sleeping or swimming. They are hand-heated to become malleable and form an airtight seal in the ear.
Advantages: Very comfortable, especially for sleeping, with good waterproofing.
Disadvantages: Less durable than other materials, they need to be replaced more frequently.
4. Thermoplastic
Description: Thermoplastic is a material that can be molded when heated. It is often used for custom caps.
Application: This material is used to manufacture custom-molded earplugs, which offer a perfect fit to the user’s ear.
Advantages: Exceptional comfort, reusable, and often used for specific applications such as music or water sports.
Disadvantages: Higher cost and require professional molding.
In short, earplugs are mainly made of foam, silicone, wax and thermoplastic, each material being chosen for its specific properties according to its intended use.
How do I put in earplugs?
Correctly fitting earplugs is essential for good hearing protection. Here are the steps for correctly inserting earplugs, depending on their type:
Direct insertion: These plugs are designed to fit your ear canal perfectly. Simply insert the plug into the ear, following the natural shape of the mold.
Fitting: Make sure the plug is securely in place and that there are no gaps that could allow noise to pass through.
General advice :
Never push the plugs in too deeply: This could cause pain or damage the ear canal.
Clean your hands before insertion: This reduces the risk of introducing dirt or bacteria into the ear.
Check the seal: After insertion, make sure the plugs are effective at reducing noise. If you still hear a lot of noise, readjust them.
By following these steps, you’ll be able to insert your earplugs correctly for optimum hearing protection.
You are interested in our solutions and want to know more? Please fill out the form below. If you would like to learn more about our hearing solutions, please click here.
