Hearing Instruments

Based on its unique 3D technology, 3Shape offers an integrated solution for the digital production of customized hearing aid shells and earmolds.

Overview of the production process

3Shape's system for the digital production of customized hearing aids replaces a labor-intensive process with one that is fully computer-driven and relies on state-of-the art technology. The hearing aids produced with the system typically offer a significantly better fit with the user's ear and therefore better perfomance than hearing aids produced in the traditional way. The system moreover guarantees consistent levels of quality.

The following figure gives an overview of the typical production flow in the system supplied by 3Shape:

Description of the hearing aid production system provided by 3Shape

At the entry of the system, an operator enters the details of the order (customer and clinic data, type of hearing aid, electronics components) into a computer. All data will be automatically available at any step of the production process when 3Shape's ShellManager^TM is implemented.

The operator then creates an accurate 3D copy of the user's ear impression (typically taken by an audiologist) by inserting the non-processed impression into 3Shape's S-200^TM or Legato^TM and simply pressing one button in the 3D scanning software.

After a few minutes, an accurate 3D digital replica of the ear impression is available on screen. Using 3Shape's modeling software, ShellDesigner^TM, the operator transforms this 3D ear impression into a finished 3D shell. The resulting 3D shell includes all the hearing aid's features, such as ventilation channel, sound in- and output.

All the above operations can be completed in a few minutes.

The 3D shells are then automatically manufactured on a rapid prototyping machines (not supplied by 3Shape) with which the system fully interfaces (read about 3D PrintManager^TM here). If necessary, existing faceplates that hold the electronic components onto the shell can also be integrated into the process. In this case, a milling path is generated by the software and sent to a CNC machine (not supplied by 3Shape) that automatically mills the faceplate to perfectly fit the newly modeled shell.

Alternatively, the part of the shell holding the traditional faceplate module can directly be 3D printed with the shell.

At the end of the process, the operator simply needs to mount the components into the shell, assisted by 3D instructions displayed by the system.

Main features of the hearing aid production system

• Ease of use - all the elements supplied by 3Shape offer a very intuitive and consistent interface. The objective is to ensure that current production personnel can use the system with a minimum of training
• Performance - the hardware and software components supplied by 3Shape offer superior results in terms of accuracy and computing speed
• Flexibility - most features and parameters can be adapted to a given hearing aid producer's specifications
• System interface with each other and with third-party equipment; this guarantees a seamless flow of data 

Advantages of the system

By implementing 3Shape's digital production system, hearing aid and earmolds producers are provided with a number of tangible benefits compared to their current production methods:

• Improved and consistent quality - unlike the shells produced manually, shells or earmolds produced by the system accurately replicate the unique geometry of the user's unique ear and ear canal. Moreover, the system offers unprecedented opportunities to accurately verify the shell produced to ensure high and consistent levels of production quality 
• Perfect fit in the user's ear and improved comfort. This translates into increased user satisfaction and fewer returns and remakes 
• Flexibility in implementation - the different elements of the system can be implemented in different locations. All data are transferred over the Internet or a local area network (LAN) 
• Reduced production time 
• Reduced production costs - since the system is digital, human interaction is kept at a minimum 
• Storage and analysis of user's profiles - the customer's ear impressions are always available in a database, which allows for quasi-automatic replacement of a lost/damaged shell as well as for detailed analysis of a shell in 3D