Hearing Device Having a Shell that Includes a Compressible Region and Methods of Manufacturing the Same

An exemplary hearing device may comprise an in-the-ear (“ITE”) component comprising a shell that is custom formed of a soft material by additive manufacturing to fit at least partially within an ear canal of the user. The shell may include a compressible region provided along an outer surface of the shell that is configured to contact a wall of the ear canal. The compressible region may be deformable due to a cavity that is located within the shell in the compressible region and that is configured to deform and/or compress when the ear canal deforms while the ITE component is inserted within the ear canal of the user.

BACKGROUND INFORMATION

Hearing devices (e.g., hearing aids, earbuds, etc.) may enable or enhance hearing by providing audio content received by the hearing device to a user. In certain examples, hearing devices may be configured to process a received input sound signal (e.g., ambient sound) and provide the processed input sound signal to the user (e.g., by way of a receiver (e.g., a speaker) placed in the user's ear canal or at any other suitable location). In addition, such hearing devices are typically customized for a user based on various factors associated with the user such as the user's particular hearing loss characteristics, the desired components of the customized hearing device, aesthetic preferences of the user, and/or the amount of ear space (e.g., within an ear canal of the user) available to receive the customized hearing device.

A customized hearing device typically includes a shell that may house various components of the hearing device, in particular an electro-acoustic transducer in the form of a so-called receiver for reproducing electric audio signals as sound, and that is configured to fit at least partially within the ear canal of a user. The shell may be attached directly to the hearing device or it may be a part of an earpiece of the hearing device which is intended to be at least partially inserted into the ear canal. A shell for a hearing device is typically made of either a rigid material such as acrylic or titanium or a soft material such as silicone or polyurethane. A customized shell may improve placement and/or retention of the hearing device in the ear canal as compared to non-customized shells due to increased surface area contact of the customized shell with respect to a wall of the ear canal. However, even with such improved placement and/or retention, a customized shell made of acrylic or titanium is still susceptible to acoustic feedback due to being uniformly rigid and poor retention and/or migration. In addition, a customized shell made of a soft material is also susceptible to poor retention and/or migration due to changes that may occur in ear canal shape during use of the hearing device. For example, jaw movements (e.g., due to chewing or talking) may modulate space within the ear canal and negatively affect retention of the shell within the ear canal. Because shells made of soft material such as silicone or polyurethane are basically incompressible in one or more areas, such jaw movements may decrease space in certain areas of the ear canal and push the wall of the ear canal against the shell. This may increase pressure felt by the user in those areas, resulting in discomfort to the user and/or reduced wearability of the hearing device.

DETAILED DESCRIPTION

Hearing devices having a shell that includes a compressible region and methods of manufacturing the same are described herein. Such hearing devices may be configured to facilitate hearing by a user. As will be described in more detail below, an exemplary hearing device may comprise an ITE component comprising a shell that is custom formed of a soft material by additive manufacturing to fit at least partially within an ear canal of the user. The ITE component is also sometimes referred to as an earpiece of the hearing device. The shell of the ITE component may include a compressible region provided along an outer surface of the shell that is configured to contact a wall of the ear canal. The compressible region may be compressible due to a cavity that is located within the shell in the compressible region and that is configured to be compressed when the ear canal deforms while the ITE component is inserted within the ear canal of the user. The compressible region may have a comparatively higher compressibility than other regions of the shell provided along the outer surface of the shell. Some embodiments may have a shell having an incompressible region provided along the outer surface of the shell that is configured to contact a wall of the ear canal. Some embodiments may have a shell that is made from a material that is soft but incompressible. As used herein, the expression “compressible” may refer to a deformation that includes a change of volume as opposed to a displacement of material as in bending a soft and/or flexible but incompressible material.

By providing hearing devices such as those described herein, it may be possible to improve retention and/or wearing comfort of an ITE component within an ear canal of a user even when the geometry of the ear canal changes (e.g., due to jaw movements) during use of the hearing device. In addition, because hearing devices such as those described herein include shells having a compressible region, it may be possible to maintain tactile push-ability of the ITE component while increasing comfort and wearability of the ITE component as compared to conventional ITE components. Moreover, hearing devices such as those described herein that include shells having a compressible region may have improved acoustic performance because they may be less likely to have an acoustic feedback problem while the hearing device is worn by a user (e.g., during mastication or speaking). Other benefits of the hearing devices and methods described herein will be made apparent herein.

As will be described further herein, hearing devices manufactured according to principles described herein include a customized shell that is formed by an additive manufacturing process and that includes a compressible region. As used herein, a “hearing device” may be implemented by any device or combination of devices configured to output sound to a user and that includes components that are worn at least partially in an ear canal of the user. For example, a hearing device may be implemented by a hearing aid configured to amplify audio content to a recipient, a sound processor included in a cochlear implant system configured to apply electrical stimulation representative of audio content to a recipient, a sound processor included in a stimulation system configured to apply electrical and acoustic stimulation to a recipient, or any other suitable hearing prosthesis. In some examples, a hearing device may be implemented by an ITE component configured to at least partially be inserted within an ear canal of a user. In some examples, a hearing device may include a combination of an ITE component, a BTE component, and/or any other suitable component.

In certain examples, hearing devices such as those described herein may be implemented as part of a binaural hearing system. Such a binaural hearing system may include a first hearing device associated with a first ear of a user and a second hearing device associated with a second ear of a user. In such examples, the hearing devices may each be implemented by any type of hearing device configured to provide or enhance hearing to a user of a binaural hearing system. In some examples, the hearing devices in a binaural system may be of the same type. For example, the hearing devices may each be hearing aid devices. In certain alternative examples, the hearing devices may be of a different type. For example, a first hearing device may be a hearing aid and a second hearing device may be a sound processor included in a cochlear implant system.

In some examples, a hearing device may additionally or alternatively include earbuds, headphones, hearables (e.g., smart headphones), and/or any other suitable device that may be used to provide sound to a user. In such examples, the user may correspond to either a hearing impaired user or a non-hearing impaired user.

FIG.1illustrates an exemplary hearing device100that is configured to assist a user in hearing. As shown, hearing device100may include, without limitation, a memory102, a processor104, and an ITE component106selectively and communicatively coupled to one another. Memory102and processor104may each include or be implemented by hardware and/or software components (e.g., processors, memories, communication interfaces, instructions stored in memory for execution by the processors, etc.). In some examples, memory102and processor104may be housed within or form part of ITE component106. In some examples, memory102and processor104may be located separately from ITE component106(e.g., in a BTE component). In some alternative examples, memory102and processor104may be distributed between multiple devices (e.g., multiple hearing devices in a binaural hearing system) and/or multiple locations as may serve a particular implementation.

Memory102may maintain (e.g., store) executable data used by processor104to perform any of the operations associated with hearing device100. For example, memory102may store instructions108that may be executed by processor104to perform any of the operations associated with hearing device100assisting a user in hearing. Instructions108may be implemented by any suitable application, software, code, and/or other executable data instance.

Memory102may also maintain any data received, generated, managed, used, and/or transmitted by processor104. For example, memory102may maintain any suitable data associated with a hearing loss profile of a user, fitting parameters used to fit hearing device100to the user, etc. Memory102may maintain additional or alternative data in other implementations.

Processor104is configured to perform any suitable processing operation that may be associated with hearing device100. For example, when hearing device100is implemented by a hearing aid device, such processing operations may include monitoring ambient sound and/or representing sound to a user via an in-ear receiver. Processor104may be implemented by any suitable combination of hardware and software.

FIG.2shows an exemplary implementation200of ITE component106. As shown inFIG.2, ITE component106may be inserted at least partially within an ear canal202of a user while ITE component106is worn by the user. In the example shown inFIG.2, ITE component106is connected to a BTE component204by way of a cable206.

As shown inFIG.2, ITE component106includes a shell208that may be custom formed by additive manufacturing to fit at least partially within the ear canal202of the user. As used herein, “additive manufacturing” refers to a process in which material is deposited (e.g., layer by layer) or arranged in precise locations to form an object. Additive manufacturing as used herein does not include casting or molding processes. Shell208may be custom formed using any suitable additive manufacturing process as may serve a particular implementation. For example, shell208may be three-dimensionally (“3D”) printed to uniquely fit within ear canal202of the user shown inFIG.2. Examples of additive manufacturing technologies that may be used to form shell208may include, for example, Digital Light Processing (“DLP”), Stereolithography (“SLA”), Fusion Deposition Modeling (“FDM”), Selective Laser Sintering (“SLS”), volumetric printing, or any other suitable additive manufacturing methodology.

Shell208may be formed of any suitable soft resilient material as may serve a particular implementation. For example, shell208may be formed of silicone, polyurethane, and/or methacrylate in certain examples. In certain examples, the material used to form shell208may have a softness of approximately Shore A 20-80 on the Durometer Shore A Hardness Scale. In certain alternative implementations, the material used to form shell208may have a softness of approximately Shore A 50-60 on the Durometer Shore A Hardness Scale.

ITE component106may be configured to fulfill two competing needs, retention within ear canal202and comfort for the user. With retention, it is desirable that ITE component106remains substantially fixed during all activities that may be performed by the user such as during eating, speaking, moving, etc. Such retention is desirable because a good seal by ITE component106along the circumference of ear canal202further enhances acoustic performance. With comfort, it is desirable to configure ITE component106such that the user does not feel discomfort during use of hearing device100.

While ITE component106is inserted within ear canal202, the natural shape of ear canal202may change. For example, jaw movements may cause the temporomandibular joint to deform ear canal202in the direction of arrow210inFIG.2. In conventional ITE components, such movement may cause discomfort to the user even though the conventional ITE components may be made of a soft material (e.g., silicone). This is because a material such as silicone is substantially incompressible. However, ITE component106includes a compressible region212that is provided along an outer surface of shell208and that is configured to contact a wall of ear canal202. Compressible region212may be compressible due to a cavity (not shown) that is located within shell208in compressible region212. Such a cavity may be configured to be compressed and deformed when ear canal202deforms while ITE component106is inserted within ear canal202. ITE component106may include any suitable number of cavities in a compressible region as may serve a particular implementation. For example, ITE component106may include a single cavity in compressible region212. Alternatively, ITE component106may include two or more cavities in compressible region212in certain implementations.

Although only one compressible region212is illustrated inFIG.2, it is understood that shell208of ITE component106may include any suitable number of compressible regions as may serve a particular implementation. For example, ITE component106may include a first compressible region (e.g., compressible region212) and a second compressible region that may be separate from the first compressible region. In certain examples, the compressible regions of a shell of ITE component106may have the same level or amount of compressibility. Alternatively, the compressible regions may have different levels or amounts of compressibility. For example, the first compressible region may be relatively more easily compressible than the second compressible region.

In certain examples, the soft material that forms shell208may be at least one order of magnitude less compressible than compressible region212(e.g., less compressible than the fluid or gas within the cavity in compressible region212). In certain alternative examples, the soft material that forms shell208may be more than three orders of magnitude less compressible than compressible region212. In certain examples, the soft material that forms shell208may be between 3-5 orders of magnitude less compressible than compressible region212.

In certain examples, cavities such as those described herein may be filled with a gas such as air. With such a configuration, the air within the cavity may compress when the shape of ear canal202changes, leading to compression of compressible region212. In certain examples, cavities such as those described herein may be filled with another compressible fluid as e.g., any suitable type of gas other than air. For example, cavities such as those described herein may be filled with nitrogen in certain examples. In certain alternative examples, a cavity may be filled partially or fully with a foam that facilitates compressible region212compressing due to a change in the dimensions of ear canal202.

Compressible region212may have any suitable number of cavities as may serve a particular implementation. In certain examples, compressible region212or shell208may have only one cavity, only two cavities, or only three cavities. In certain examples, compressible region212or shell208may have no more than eight total cavities. In certain alternative examples, compressible region212or shell208may have no more than four total cavities.

Cavities such as those described herein may have any suitable size and/or shape as may serve a particular implementation. In certain examples, a cavity may be at least one millimeter across (e.g., when viewed in cross section). In certain alternative examples, a cavity may be two or more millimeters across (e.g., when viewed in cross section). In certain examples, cavities such as those described herein may define an inner volume of approximately 0.5 cubic millimeters. (e.g., corresponding to a sphere having a diameter of approximately one millimeter). In certain examples, a cavity may define inner volume of approximately four cubic millimeters (e.g., corresponding to a sphere having a diameter of approximately two millimeters). It is understood that macroscopic cavities such as those described herein are distinguished at least based on size from microscopic cavities such as those that may be found in, for example, a compressible foam structure. Examples of cavities that may be provided within a shell of an ITE component are described herein.

Compressible region212may be located at any suitable portion of shell208as may serve a particular implementation. For example, compressible region212may be located on shell208such that, when ITE component106is worn by the user, compressible region212contacts a portion of ear canal202that changes shape with jaw movements of the user. Additionally or alternatively, compressible region212may be positioned at a location that is configured to contact a bend in ear canal202or at any other suitable location.

In the example shown inFIG.2, compressible region212is defined by a dashed line boundary on an outer surface of shell208. Portions of shell208that are outside of the dashed line boundary may be either less compressible than compressible region212or not compressible at all. In certain examples, shell208may be configured to not deform in a cartilaginous part of ear canal202to provide good retention within ear canal202. However, to keep an acoustic seal and improve retention while being comfortable for the user, shell208may be configured to be compressible in compressible region212were ear canal202deforms (e.g., due to jaw movements).

In the example shown inFIG.2, the boundary of compressible region212that is indicated by the dashed line is provided for illustrative purposes. It is understood that in certain implementations shell208may or may not include a visible boundary that separates compressible region212from other portions of shell208.

FIG.3illustrates a cross sectional view of an exemplary configuration of ITE component106that may be implemented in certain examples. As shown inFIG.3, ITE component106may include a shell302that may be formed of any suitable soft material such as described herein. Shell302includes a vent channel304, an elongate receptacle306that extends along a longitudinal length of shell302, and compressible region308where a cavity310is located within shell302. In the example shown inFIG.3, cavity310is completely encapsulated or embedded within shell302and is surrounded by the material of shell302. Cavity310is configured to be compressed when ear canal202deforms while ITE component106is worn by a user. Cavity310is shown as having an oval shaped cross section inFIG.3. However, it is understood that cavities such as those described herein may have any suitable size and/or shape as may serve a particular implementation.

In the example shown inFIG.3, compressible region308and cavity310only extend along a portion of the longitudinal length of shell302. A portion312of shell302to the right of compressible region308inFIG.3may be considered as a region that is relatively less compressible than compressible region308or that is not compressible (e.g., incompressible) due to the type of material used to form shell302. In certain examples, portion312of shell302to the right of compressible region308may correspond to a portion of shell302that is configured to contact a cartilaginous part of ear canal202while ITE component is worn by a user. Portion312is shown inFIG.3as merely an example where either a less compressible or an incompressible region of a shell may be located in certain implementations. In is understood that a less compressible or an incompressible region may be positioned in other areas in other implementations. For example, a portion of shell302to the left of compressible region308may correspond to a less compressible or an incompressible region in certain examples. Additionally or alternatively, all or part of a surface on an upper side of shell302shown inFIG.3may correspond to a less compressible or an incompressible region in certain examples.

In the example shown inFIG.3, a housing314is positioned within elongate receptacle306. Housing314may include any suitable component (e.g., a receiver, communication devices, batteries, sensors, sound or air tube, etc.) that may be associated with ITE component106.

FIG.4illustrates a cross sectional view of an additional exemplary configuration of ITE component106that may be implemented in certain examples. As shown inFIG.4, ITE component106may include a shell402that may be formed of any suitable soft material such as described herein. Shell402is similar to shell302in that shell402includes vent channel304and elongate receptacle306that extends along a longitudinal length of shell402. However, shell402includes a compressible region404where a plurality of cavities (e.g., cavities406-1through406-3) are located within shell402. Cavities406may be configured to be compressed and deformed when ear canal202deforms while ITE component106is inserted within ear canal202. Portion408shown inFIG.4may correspond to either a less compressible or an incompressible region of shell402.

In certain examples, one or more cavities within a shell of ITE component106may be open on one end to elongate receptacle306. In such examples, the one or more cavities may be sealed on the one end by an object that is inserted within elongate receptacle306. To illustrate an example,FIG.5shows another exemplary configuration of ITE component106. As shown inFIG.5, ITE component106may include a shell502that includes a compressible region504having a plurality of cavities506(e.g., cavities506-1through506-3). Cavities506are each open on one end to elongate receptacle306. However, in the example shown inFIG.5, a sleeve508is provided within elongate receptacle306to seal cavities506. Housing314is provided within sleeve508. Portion510shown inFIG.5may correspond to either a less compressible or an incompressible region of shell502.

In certain examples, sleeve508and/or elongate receptacle306may include one or more sleeve insertion guides to facilitate proper placement of sleeve508within elongate receptacle306. For example, sleeve508may include one or more ribs on an external surface thereof that are configured to be received by one or more corresponding grooves on a surface of elongate receptacle306.

In certain examples, a housing such as housing314may be used to seal one or more cavities within a shell instead of a sleeve such as sleeve508. To illustrate,FIG.6shows another exemplary configuration where housing314is configured to seal cavities. As shown inFIG.6, ITE component106may include a shell602that includes a compressible region604that includes a plurality of cavities606(e.g., cavities606-1through606-3) that are formed within shell602. As shown inFIG.6, each of cavities606may be open on one end to elongate receptacle306. However, in the example shown inFIG.6, housing314is configured to seal cavities606instead of an additional object such as sleeve508. Portion608of shell602shown inFIG.6may correspond to either a less compressible or an incompressible region of shell602.

In certain examples, the process for additively manufacturing a shell of ITE component106may result in excess (e.g., uncured) material being located within a cavity of the shell. In such examples, one or more openings may be provided into the cavity to facilitate removing the excess material. For example, the shell may include an inlet connecting the cavity to an exterior of the shell and an outlet connecting the cavity to an exterior of the shell. To illustrate,FIG.7shows an exemplary implementation700of a semifinished shell702that may be used to form shell302shown inFIG.3. As shown inFIG.7, an inlet704may connect an exterior of shell702to cavity310and an outlet706may connect cavity310to the exterior of shell702. The excess material that may be located within cavity during manufacture may be expelled from cavity310in any suitable manner. For example, pressurized air may be injected into inlet704to expel the excess material out of outlet706. Additionally or alternatively, centrifugation may be used to expel excess material from cavity310of semifinished shell702. Additionally or alternatively, washing liquids such as isopropanol, ethyl acetate, or acetone may be provided into inlet704to wash the excess material out of outlet706. Portion708of shell702shown inFIG.7may correspond to either a less compressible or an incompressible region of shell702.

Semifinished shell702may be considered as being only partially finished due to the presence of inlet704and outlet706. After the excess material is removed, inlet704and outlet706may be closed in any suitable manner (e.g., using glues, plugs, lacquers, resins, etc.) to result, for example, in the configuration of cavity310shown inFIG.3.

FIG.8shows an additional exemplary implementation800of a semifinished shell802that may be used to form shell402shown inFIG.4. As shown inFIG.8, a plurality of inlets804(e.g., inlets804-1through804-3) connect cavities406to an exterior of semifinished shell802by way of elongate receptacle306. For example, inlet804-1connects cavity406-1to the exterior of semifinished shell802, inlet804-2connects cavity406-2to the exterior of semifinished shell802, and inlet804-3connects cavity406-3to the exterior of semifinished shell802. In addition, a plurality of outlets806(e.g., outlets806-1through806-3) connect cavities406to the exterior of semifinished shell802. For example, outlet806-1connects cavity406-1to the exterior of semifinished shell802, outlet806-2connects cavity406-2to the exterior of semifinished shell802, and outlet806-3connects cavity406-3to the exterior of semifinished shell802. In certain examples, excess material left in cavities406may be removed from cavities406in any suitable manner such as described herein. After the excess material is removed, inlets804and outlets806may be closed in any suitable manner such as described herein to result, for example, in the configuration of cavities406shown inFIG.4. Portion808of shell802shown inFIG.8may correspond to either a less compressible or an incompressible region of shell802.

In certain examples, a support structure may be provided within a cavity of a shell of an ITE component. The properties of such a support structure may be specifically selected based on a desired amount of compressibility of a compressible region. Such a support structure may be configured in any suitable manner. For example, in certain implementations, a support structure may include at least one of a lattice support structure, a tree-like support structure, a beam structure, and/or a strut structure. To illustrate,FIG.9shows another exemplary configuration900of a semifinished shell902that may be implemented in certain examples. As shown inFIG.9, shell902includes a compressible region904that includes a cavity906. Within cavity906, a lattice structure908is provided to give structural support to cavity906. In certain examples, the amount and/or the thicknesses of the lattices included in lattice structure908may be specifically selected based on a desired amount of compressibility of compressible region904. As shown inFIG.9, semifinished shell902also includes an inlet910connecting cavity906to an exterior of semifinished shell902and an outlet912connecting cavity906to the exterior of semifinished shell902. Inlet910and outlet912may be used in any suitable manner such as described herein to remove excess material from cavity906during manufacture. Portion914of shell902shown inFIG.9may correspond to either a less compressible or an incompressible region of shell902.

FIG.10shows an additional exemplary configuration1000of a semifinished shell1002that may be implemented in certain examples. As shown inFIG.10, semifinished shell1002includes a compressible region1004that includes a cavity1006in which a tree-like structure1008is provided to give structural support to cavity1006. In certain examples, the amount and/or thicknesses of the branches included in tree-like structure1008may be specifically selected based on a desired amount of compressibility of compressible region1004. As shown inFIG.10, semifinished shell1002also includes an inlet1010connecting cavity1006to an exterior of semifinished shell1002and an outlet1012connecting cavity1006to the exterior of semifinished shell1002. Inlet1010and outlet1012may be used in any suitable manner such as described herein to remove excess material from cavity1006during manufacture. Portion1014of shell1002shown inFIG.10may correspond to either a less compressible or an incompressible region of shell1002.

In certain examples, a support structure such as described herein may be provided on an inner surface of a cavity and may only extend partially into the cavity to stiffen the inner surface of the cavity. For example, in certain implementations, lattice structure908may only extend partially towards a center of cavity906to stiffen the inner surface of cavity906. In such examples, a central region of cavity906may not include any lattices or other support structure.

A shell of ITE component106such as any of those described herein may be manufactured using any suitable manufacturing process as may serve a particular implementation.FIG.11shows an exemplary hearing device manufacturing system1100(“system1100”) that may be used to manufacture hearing device100including the shell of ITE component106.

As shown inFIG.11, system1100may include, without limitation, a memory1102and a processor1104selectively and communicatively coupled to one another. Memory1102and processor1104may each include or be implemented by hardware and/or software components (e.g., processors, memories, communication interfaces, instructions stored in memory for execution by the processors, etc.). In some examples, memory1102and processor1104may be housed within or form part of a single computing device configured to control a manufacturing process of a shell of ITE component106. In some alternative examples, memory1102and processor1104may be distributed between multiple devices and/or multiple locations as may serve a particular implementation.

Memory1102may maintain (e.g., store) executable data used by processor1104to perform any of the operations associated with manufacturing a shell of ITE component106. For example, memory1102may store instructions1106that may be executed by processor1104to perform any of the operations associated with forming one or more cavities within a shell of an ITE component. Instructions1106may be implemented by any suitable application, software, code, and/or other executable data instance.

Memory1102may also maintain any data received, generated, managed, used, and/or transmitted by processor1104. For example, memory1102may maintain any suitable data associated with shapes of shells, scans of ear canals of particular users, ear canal shape data, processing parameters used to generate deformable and/or compressible regions of shells with different moduli of elasticity, hearing device components, etc. Memory1102may maintain additional or alternative data in other implementations.

Processor1104is configured to perform any suitable processing operation that may be associated with manufacturing ITE component106of hearing device100. Processor1104may be implemented by any suitable combination of hardware and software.

As described above, the shell of ITE component106may be custom formed for the user to fit at least partially within an ear canal of a user. In such examples, system1100may access, generate, or otherwise obtain any information that defines one or more spaces associated with an ear of a user where a customized hearing device may be worn by the user.

In certain examples, system1100may generate or otherwise obtain a 3D scan of an ear of a user. Such a 3D scan may define an available amount of space within an ear canal of the user where ITE component106of a customized hearing device may be inserted.

System1100may obtain a 3D scan in any suitable manner. In certain implementations, system1100may generate a 3D scan by directly scanning an ear of a user. For example, system1100may use any suitable 3D scanning device to directly scan the recesses, contours, etc. of an ear of the user to generate a 3D scan. In certain examples, system1100may use a 3D scanner to directly scan inside an ear canal of the user. In such examples, a 3D scan may provide information indicating an amount of space available within the ear canal for a customized hearing device.

In certain examples, system1100may obtain multiple 3D scans of an ear canal of a particular user to facilitate manufacturing ITE component106. For example, system1100may obtain a first 3D scan of the ear canal while the jaw of the user is in a first state, a second 3D scan of the ear canal while the jaw of the user is in a second state, and a third 3D scan of the ear canal while the jaw of the user is in a third state. The first, second, and third states may correspond to any suitable state of the jaw of the user that may be useful to provide information regarding changes that may occur in the shape of the ear canal as a result of jaw position or movement. For example, the first state may correspond to an open mouth state, the second state may correspond to a clenched jaw state, and the third state may correspond to a closed mouth state. System1100may compare the first 3D scan, the second 3D scan, and the third 3D scan in any suitable manner to determine where the shape of the ear canal of the user changes as a result of the different states of the jaw of the user. System1100may then use such information to determine suitable positions of one or more compressible regions of a shell of ITE component106.

In certain alternative implementations, system1100may generate a 3D scan by scanning an impression made of an ear of a user. For example, during a customized hearing device manufacturing process, an audiologist or the like may insert a shape-forming material (e.g., silicone) into an ear canal of a user. The shape-forming material is configured to retain the shape defining the dimensions of the ear canal when removed from the ear canal. After the impression is removed from the ear canal, system1100may use any suitable 3D scanner to 3D scan the impression to generate a 3D scan of the ear canal.

In certain examples, multiple impressions may be made of the ear of the user at different states of the jaw of the user such as those described herein. For example, a first impression of the ear canal may be made while the jaw of the user is in a first state, a second impression of the ear canal may be made while the jaw of the user is in a second state, and a third impression of the ear canal may be made while the jaw of the user is in a third state. System1100may scan the first, second, and third impressions in any suitable manner such as described herein to generate multiple different 3D scans of the ear canal. Similar to that described above, system1100may compare the 3D scans in any suitable manner to determine suitable positions for one or more compressible regions of a shell of ITE component106.

In certain alternative examples, the shell of ITE component106may be formed so as to fit any one of a plurality of different users as opposed to being custom formed for a particular user.

Based on the dimensions of the ear canal of the user, system1100may generate a 3D model of the shell of the ITE component of the hearing device. In generating the 3D model, system1100may take into account any suitable information associated with the user and/or the hearing device. For example, system1100may use information (e.g., statistical information, ear shape intelligence, etc.) about optimal placement of a compressible region of a shell. Additionally or alternatively, system1100may use information regarding placement of components (e.g., a vent, sensor(s), a receiver, a removal filament, cerumen protection, etc.) to be included in the hearing device when determining where to position a compressible region of a shell. Additionally or alternatively, the generating of the 3D model may include adding support structures to one or more cavities to facilitate printing and/or decrease compressibility of a cavity to a desired value. System1100may generate the 3D model in any suitable manner using any suitable 3D modeling program.

Based on the 3D model, system1100may additively manufacture the shell of ITE component106. System1100may use any suitable additive manufacturing process to form the shell of ITE component106such as those described herein. For example, system1100may use DLP to form the shell of an ITE component out of silicone.

In certain examples, system1100may be configured to facilitate removal of excess (e.g., uncured) material from one or more cavities of a semifinished shell. This may be accomplished in any suitable manner. For example, pressurized air, liquid washes, centrifugation (e.g., in a heated or non-heated centrifuge), and/or evaporation in an oven may be used to remove excess material from one or more cavities of a shell of ITE component106. In such examples, the additively manufacturing of the shell may include forming inlets/outlets such as those described herein to facilitate removal of the excess material.

In certain examples, system1100may perform or otherwise facilitate any suitable post processing operations after additively manufacturing the shell. For example, system1100may facilitate closing inlets/outlets of one or more cavities in shells, ultraviolet (“UV”) post curing, washing, high temperature curing, and/or any other suitable process.

The finishing of the assembly of hearing device100may include, for example, a lacquer process, component insertion (e.g., insertion of housing314within elongate receptacle306), serialization, and/or any other finishing process for hearing device100.

The preceding disclosure describes various exemplary shells of ITE component106that are configured to fit at least partially within an ear canal. However, it is understood that principles such as those described herein may be used to manufacture other components of hearing device100and/or any other suitable device. For example, principles such as those described herein may be used to manufacture a housing of a BTE component such that the housing of the BTE component includes a compressible region.

FIG.12illustrates an exemplary method1200for manufacturing a hearing device according to principles described herein. WhileFIG.12illustrates exemplary operations according to one embodiment, other embodiments may omit, add to, reorder, and/or modify any of the operations shown inFIG.12. One or more of the operations shown inFIG.12may be performed by a hearing device manufacturing system such as hearing device manufacturing system1100, any components included therein, and/or any implementation thereof.

At operation1202, a hearing device manufacturing system such as hearing device manufacturing system1100may access dimensions of an ear canal of a user of a hearing device. Operation1202may be performed in any of the ways described herein. For example, a hearing device manufacturing system (e.g., system1100) may generate or receive 3D scan information of an ear canal of a user.

At operation1204, the hearing device manufacturing system may generate, based on the dimensions of the ear canal of the user, a 3D model of a shell of an ITE component of the hearing device. Operation1204may be performed in any of the ways described herein.

At operation1206, the hearing device manufacturing system may additively manufacture, based on the 3D model and using a soft material, the shell of the ITE component of the hearing device. For example, the hearing device manufacturing system may instruct a 3D printing device to 3D print the shell based on the 3D model. As described herein, the shell is additively manufactured so as to include a compressible region provided along an outer surface of the shell, the compressible region configured to contact a wall of the ear canal. The compressible region is configured to be compressible due to a cavity that is located within the shell in the compressible region. Operation1206may be performed in any of the ways described herein.

In some examples, a non-transitory computer-readable medium storing computer-readable instructions may be provided in accordance with the principles described herein. The instructions, when executed by a processor of a computing device, may direct the processor and/or computing device to perform one or more operations, including one or more of the operations described herein. Such instructions may be stored and/or transmitted using any of a variety of known computer-readable media.

A non-transitory computer-readable medium as referred to herein may include any non-transitory storage medium that participates in providing data (e.g., instructions) that may be read and/or executed by a computing device (e.g., by a processor of a computing device). For example, a non-transitory computer-readable medium may include, but is not limited to, any combination of non-volatile storage media and/or volatile storage media. Exemplary non-volatile storage media include, but are not limited to, read-only memory, flash memory, a solid-state drive, a magnetic storage device (e.g., a hard disk, a floppy disk, magnetic tape, etc.), ferroelectric random-access memory (“RAM”), and an optical disc (e.g., a compact disc, a digital video disc, a Blu-ray disc, etc.). Exemplary volatile storage media include, but are not limited to, RAM (e.g., dynamic RAM).

FIG.13illustrates an exemplary computing device1300that may be specifically configured to perform one or more of the processes described herein. As shown inFIG.13, computing device1300may include a communication interface1302, a processor1304, a storage device1306, and an input/output (“I/O”) module1308communicatively connected one to another via a communication infrastructure1310. While an exemplary computing device1300is shown inFIG.13, the components illustrated inFIG.13are not intended to be limiting. Additional or alternative components may be used in other embodiments. Components of computing device1300shown inFIG.13will now be described in additional detail.

Communication interface1302may be configured to communicate with one or more computing devices. Examples of communication interface1302include, without limitation, a wired network interface (such as a network interface card), a wireless network interface (such as a wireless network interface card), a modem, an audio/video connection, and any other suitable interface.

Processor1304generally represents any type or form of processing unit capable of processing data and/or interpreting, executing, and/or directing execution of one or more of the instructions, processes, and/or operations described herein. Processor1304may perform operations by executing computer-executable instructions1312(e.g., an application, software, code, and/or other executable data instance) stored in storage device1306.

Storage device1306may include one or more data storage media, devices, or configurations and may employ any type, form, and combination of data storage media and/or device. For example, storage device1306may include, but is not limited to, any combination of the non-volatile media and/or volatile media described herein. Electronic data, including data described herein, may be temporarily and/or permanently stored in storage device1306. For example, data representative of computer-executable instructions1312configured to direct processor1304to perform any of the operations described herein may be stored within storage device1306. In some examples, data may be arranged in one or more databases residing within storage device1306.

In some examples, any of the systems, hearing devices, and/or other components described herein may be implemented by computing device1300. For example, memory102or memory1102may be implemented by storage device1306, and processor104or processor1104may be implemented by processor1304.