Method for manufacturing an ear device having a retention element

Abstract

A method for manufacturing a first ear device having a first retention element to be worn at least in part in at least one of the outer ear and the ear canal of a user and a second ear device having a second retention element to be worn at least in part in at least the outer ear and the ear canal of the user. The outer surface of the first retention element is individually shaped according to the measured inner shape of the user's outer ear and ear canal; a digital data set according to a data format which is representative of the measured inner shape of the user's outer ear and ear canal is obtained; the user provided with a personal copy of the digital data set for personal use by the user; and the personal copy of the digital data set used for manufacturing the second retention element.

1 . A method for manufacturing a first ear device having a first retention element to be worn at least in part in at least one of an outer ear and an ear canal of a user and a second ear device having a second retention element to be worn at least in part in at least one of said outer ear and said ear canal of said user, comprising:
 defining a data format;   measuring an inner shape of said user's outer ear and ear canal;   manufacturing said first retention element, wherein an outer surface of said first retention element is individually shaped according to said measured inner shape of said user's outer ear and ear canal;   obtaining a digital data set according to said data format, which is representative of said measured inner shape of said user's outer ear and ear canal;   providing said user with a personal copy of said digital data set for personal use by said user;   using said personal copy of said digital data set for manufacturing said second retention element, wherein an outer surface of said second retention element is individually shaped according to said measured inner shape of said user's outer ear and ear canal.   
   
   
       2 . The method of  claim 1 , further comprising:
 permanently storing said digital data set on a personal mobile data carrier for creating said personal copy of said digital data set and providing said user with said personal mobile data carrier in order to provide said user with said personal copy of said digital data set.   
   
   
       3 . The method of  claim 2 , wherein said mobile data carrier includes a semiconductor memory for storing said digital data. 
   
   
       4 . The method of  claim 3 , wherein said semiconductor memory is part of a smart card, a mobile phone, a personal digital assistant, or a portable computer. 
   
   
       5 . The method of  claim 1 , wherein said personal copy of said digital data set is transmitted by said user to the site where said second retention element is manufactured for being used for manufacturing said second retention element. 
   
   
       6 . The method of  claim 1 , wherein said digital data set is transmitted to the site where said first retention element is manufactured and said first retention element is manufactured by using said transmitted digital data set. 
   
   
       7 . The method of  claim 1 , further comprising:
 sampling statistical data regarding changes of ear anatomy caused by aging, establishing a model based on said statistical aging data for estimating changes of ear anatomy of said user caused by aging, estimating from said model an actual shape of said user's outer ear and ear canal based on said measured shape of said user's outer ear and ear canal according to said personal copy of said digital data set by taking into account a time interval having passed since said measured shape of said user's outer ear and ear canal was measured.   
   
   
       8 . The method of  claim 7 , further comprising:
 manufacturing said second retention element based on said estimated actual shape of said user's outer ear and ear canal.   
   
   
       9 . The method of  claim 1 , wherein an inner shape of said user's outer ear and ear canal is measured while the user undergoes a military physical inspection, a blood donation, a doctor visit or a hearing protection device delivery in a company. 
   
   
       10 . The method of  claim 1 , wherein said first and second retention elements are formed by an additive layer-by-layer build-up process. 
   
   
       11 . The method of  claim 10 , wherein said first and second retention elements are formed by layer-by-layer laser sintering of a powder material including a polyamide powder. 
   
   
       12 . The method of  claim 1 , wherein said shape of said user's outer ear and ear canal is measured by three-dimensional laser scanning of said user's outer ear and ear canal. 
   
   
       13 . The method of  claim 1 , wherein said shape of said user's outer ear and ear canal is measured by forming an impression of said user's outer ear and ear canal and by subsequent three-dimensional laser scanning of said impression. 
   
   
       14 . The method of  claim 1 , wherein said first retention element is a first shell and said first ear device is a first earplug. 
   
   
       15 . The method of  claim 1 , wherein said second retention element is a second shell and said second ear device is a second earplug. 
   
   
       16 . The method of  claim 14 , wherein at least one of said first and second shell is designed for providing, when worn by said user, for an acoustic attenuation of at least 10 dB averaged over an audible frequency range. 
   
   
       17 . The method of  claim 1 , further comprising:
 permanently storing said digital data set on a stationary data carrier which is accessible by said user in order to provide said user with said personal copy of said digital data set.   
   
   
       18 . The method of  claim 17 , wherein said personal copy of said digital data set is stored on a home personal computer of said user. 
   
   
       19 . The method of  claim 17 , wherein said personal copy of said digital data set is stored in a data base which is remotely accessible by said user.