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Manufacturing Process
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When manufacturing electronic earplugs, the first critical measurement doesn't come from the lab itself... it actually comes from the provider who is making the ear impressions for you. If the impression is flawed from the initial process, then the final product will have less of a chance of being made properly and create issues such as feedback, fit hotspots and isolation leaks against harmful sounds.
In order to maintain our quality, and minimize your risks for issues occurring, we recommend that the ear impression be manufactured by syringing the impression material into the ear with a syringe, or more commonly used within medical practices, a cartridge gun. Accurate impressions will go past the second bend in the ear canal and will not have any folds, missing gaps or details of the ear cavity due to air pockets or poor impression techniques.
Once these ear impressions have finally cured and are ready to process, the provider will send them to us for scanning and digital recording into a computer CAD database. From this scan, reproducing the impression into an outer shell will eliminate the human factor of cutting away or modifying the true impression we received. Therefore, you get the true reproduction of your original impression that is laser casted for a perfect fit.
After another inspection by an ear mold technician, the shell is brought to the manufacturing area for final insertion of the circuit board and programming before final quality control and finishing touches are done. The final product is a perfect, computerized fit, that is then sent out to the waiting customer, or hearing professional for further instruction and use.
We pride ourselves for having one of the lowest 'remaking' requests in the business. We believe if we do our job correctly, then your units should have zero issues for many years to come.
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