Patent ID: 8554352

Claim:
A method for designing a hearing instrument shell for a hearing instrument for insertion into an ear canal of a user, the hearing instrument further comprising a faceplate and hearing instrument components positioned within the shell, comprising: creating a computerized virtual model of the shell, the model comprising a shell wall comprising an outer surface conforming in part to the ear canal and a shell wall interior surface; a shell interior within the shell for selectively receiving the hearing instrument components; a first, general closed canal end comprising a tip facing into the ear canal and comprising a vent opening; and a second, open end for receiving a faceplate; creating a vent within the shell interior adjacent or nearly adjacent the shell interior wall surface, the vent comprising an initial, approximately cylindrical section comprising a vent wall; a first end connected to the vent opening in the tip; and a second end extending to the second, open end of the shell; after creating the vent, designating a location for positioning the electrical components in the shell interior volume adjacent the shell wall interior surface apart from the vent and arranging the components in a configuration occupying the least amount of volume of the shell interior; and after designating a location for positioning the electrical components, expanding the cross-section of the vent to utilize a maximum volume of unoccupied space in the shell interior.