ShellDesigner

ShellDesigner^TM is at the core of the automated hearing aid production system supplied by 3Shape. This complete modeling software package is used to transform 3D ear impressions created by a 3Shape 3D scanner into 3D models of shells for ITE, ITC or CIC hearing aids in a few simple steps.

The 3D models designed in ShellDesigner^TM are ready to be manufactured automatically on 3D printing machines as fully functional hearing aid shells. The system also allows for the use of existing faceplates. Milling paths are automatically generated for accurate faceplate milling on CNC machines.

ShellDesigner^TM is characterized by easy learning, ease of use, flexibility and processing speed.

Example of a CIC and a full-concha shell modeled in ShellDesigner^TM:

Product highlights

• Intuitive interface - the software offers a fully graphical WindowsTM-based interface customized for hearing aid modeling. The operator is guided through all the steps of the production process
• User-friendliness - only basic computer knowledge is required to use the software
• Automation - most features are automated or assisted by the system
• Workflow history saved along with the 3D model - this facilitates later reference (in quality control for instance) and production of new shells for the same patient
• Ease of use - the operator has the possibility to move back and forth in the shell design process. The software modifies the model accordingly in real time
• Flexibility - ShellDesignerTM can incorporate both faceplates and module-based hearing aid components. It can model any size of shells, from CIC to full concha. Since the whole ear impression is being modeled, the user can optimize the size and appearance of the instrument to best suit the patient's ear
• Productivity - the whole modeling process can be completed in a few minutes. Reductions in labor costs are thus made possible compared to current production methods
• Easy manipulation and visualization of 3D models with SpaceballT motion control device
• Full simulation - all the components of the hearing aid, such as electronic modules, transducer, volume control, receiver, and battery container are incorporated in the modeling process to make it most complete and realistic
• Automatic retrieval of the relevant components' CAD models (when used with 3Shape's system integration solution)
• Display options - for optimal design and appearance, the hearing aid shell can be visualized alone, with electronics components, and/or inside the patient's ear
• Simultaneous modeling - possibility to model both left and right ears simultaneously for better aesthetic evaluation and consistency. User input applied to one ear is automatically transferred to the other.
• Automatic on-screen placement of components - assisted by collision detection tools
• Real-time processing - all modeling operations are performed in real time on screen. The operator can assess the results immediately

Overview of ShellDesignerTM workflow

In ShellDesigner^TM, the user is guided through the steps required to go from a raw 3D ear impression to a finished hearing aid shell. The main steps of the modeling process are the following:

1. Import of an accurate 3D replica of the patient's ear impression The 3D model has been created with 3Shape's dedicated ear impression 3D scanner. All configuration parameters and CAD models of the relevant electronics components and faceplates are automatically loaded into ShellDesignerTM	3D ear impression
2. Assisted optimization of the 3D ear impression ShellDesigner automatically optimizes the 3D model's surface by making it smoother and removing eventual artifacts (such as the thread mark left on many ear impressions)	Removal of artifacts
3. Tip fitting The software automatically cuts and rounds the top of the hearing aid shell. Various tip shapes, such as a bellbore, can be created on the shell.	Tip fitting of the ear impression
4. Venting and sound exit Customizable ventilation channel can be added in the shell. A number a predefined ventilation channel styles exist: regular, trumpet shaped, collection vents, trench vent, step vent, D-shaped, oval etc.	Creation of ventilation channel
5. Placement of electronics The program automatically creates a user-defined shell thickness and helps optimally position the faceplate, transducer, telecoil, a volume control and other components. 2D cross-sections are available to ease the placement process.	Placement of electronic components
6. Virtual faceplate When traditional faceplates are used, a CNC milling path can be generated to ensure a perfect fit of the faceplate with the shell's unique geometry (this requires a milling machine). An 'integrated faceplate' optional feature is also available: in this case the system calculates the outer shell rounding and creates a customizable locking mechanisms directly on the 3D printed shell. The software also creates a unique identifier on or in the shell.	Placement of electronic components
7. Visualization in Ear Once the shell has been completed, it can be visualized inside the original impression/ear to assess its aesthetic aspect and fit with the user's ear	Finished 3D shell visualized in the ear
8. Visualization of deviations Deviations between the original ear impression and the finished shell can easily be displayed using a detailed color map. This allows for easy analysis of the created shell's fit with the customer's ear.	Analysis of deviations between shell and original ear impression