Improved methods are described for the creation of impressions for use in the manufacture of hearing aid components. In addition methods for manufacturing components of hearing aid systems using improved ear canal impressions are described.

A guard for a space access device is configured to output air flow through a distal end portion thereof. The guard includes q housing having a proximal end opening, a distal end opening, and a filter portion positioned between the proximal and distal end openings. The filter includes a first plate having a first opening therethrough and a second plate having a second opening therethrough. When the first plate is overlaid in contact with the second plate, this forms an aperture that extends through both the first and second plates.

Embodiments of the invention are directed to a microactuator including using (i) an ingress membrane mounting ring adhesive positioned on an ingress membrane mounting surface to mount an ingress membrane and (ii) a flexible encapsulation shield mounted on a support band and extending over the ingress membrane mounting ring and (iii) a first reed adhesive connecting the ingress membrane to a microactuator reed at an ingress membrane reed opening and (iv) a second reed adhesive positioned on and covering the first reed adhesive, the second reed adhesive extending from the ingress membrane to the microactuator reed.

A method of configuring a custom insert of a charger, wherein the custom insert is for aligning a receiver charging element of a hearing device and a transmitter charging element of a charger, includes: obtaining a digital three-dimensional hearing device model comprising a representation of the receiver charging element, wherein the digital three-dimensional hearing device model is based on a digital scan of an ear; obtaining a digital three-dimensional charger model comprising a representation of the transmitter charging element; obtaining a generic digital three-dimensional insert model; obtaining a digital cavity representing a cavity in the custom insert; and creating a custom digital three-dimensional insert model based on the digital cavity and the generic digital three-dimensional insert model, such that the representation of the receiver charging element in the digital three-dimensional hearing device model and the representation of the transmitter charging element in the three-dimensional charger model, are aligned.

A method of configuring a custom insert of a charger, wherein the custom insert is for aligning a first charging element of a hearing device and a transmitter charging element of a charger, includes: obtaining a digital three-dimensional hearing device model comprising a representation of the first charging element; obtaining a digital three-dimensional charger model comprising a representation of the transmitter charging element; obtaining a digital three-dimensional insert model; obtaining a digital cavity representing a cavity in the custom insert; and creating a custom digital three-dimensional insert model based on the digital cavity and the digital three-dimensional insert model, such that the representation of the first charging element in the digital three-dimensional hearing device model and the representation of the transmitter charging element in the three-dimensional charger model, are aligned.

Systems and methods disclosed herein include a first scanner comprising an inflatable membrane configured to be inflated with a medium to conform an exterior surface of the inflatable membrane to an interior shape of a cavity, the medium attenuating, at a first rate per unit length, light having a first optical wavelength, and attenuating, at a second rate per unit length, light having a second optical wavelength; an emitter configured to illuminate an interior surface of the inflatable membrane; a detector configured to receive light from the interior surface; a processor configured to generate a first electronic representation of the interior shape based on the received light; and a design computer configured to modify the first electronic representation into a three-dimensional shape by correlating pixels of the first electronic representation with corresponding distance information from the first scanner to the inflatable membrane for each pixel.

A hearing device may include a housing, a microphone, and an acoustic element. The housing may include a shell and a microphone port disposed between an outer surface of the shell and an inner surface of the shell that defines a cavity within the shell. The microphone may be disposed within the cavity of the shell and acoustically connected to the microphone port. The acoustic element may be disposed on the outer surface of the shell or at least partially within the microphone port. The acoustic element may include a substrate and fibers extending from the substrate. At least a portion of acoustic energy incident upon the acoustic element may be received by the microphone.

A method is a described for constructing a hearing aid shell that comprises a combination of hard and soft materials. In one embodiment, 3D printing is combined with conventional mold/casting methods so that a first shell portion made of a hard material and a mold for a second shell portion are 3D printed. The mold is then filled with a soft material which is allowed to set to form the second shell portion, and the first and second shell portions are adhesively attached.

A method of manufacturing a hearing device housing including at least one opening. The method includes the steps of: designing a pre-model of the hearing device housing by 3D-modelling software, the pre-model including a protective structure covering the opening, the protective structure being prepared for removal; producing a preform of the hearing device housing based on the pre-model; and removing the protective structure thus providing the hearing device housing with the opening.

A method of manufacturing a charger insert part of a hearing instrument charger device comprising a charger casing having a receiving portion, and a first charger element, includes: obtaining a first virtual model of the rechargeable hearing instrument shaped or to be shaped to at least partly conform to a shape of a portion of an ear canal of a user, wherein the first virtual model comprises an allocated position for a second charger element; obtaining a second virtual model of the charger insert part for manufacturing the charger insert part, such that when the charger insert part is placed in the receiving portion, the first charger element will be in a relation with the second charger element; and shaping, by a manufacturing process, the charger insert part based on the second virtual model, the second virtual model being based on the first virtual model.