Abstract: In a method to create a hearing aid housing shell and a negative cast for a hearing aid to be fitted to a patient's ear canal, a 3D jet printer apparatus is provided able to build a 3D part by injecting both the soft material and a hard material with the soft material serving as a support for the hard material. The 3D file is input to the 3D jet printer apparatus to build the hearing aid shell with the hard material and the combined negative cast with the soft material. The negative cast is used to check a quality of the hearing aid shell and to add external features to the shell by fitting the shell into the negative cast.

Abstract: A receiver for a receiver-in-the-canal hearing instrument can be securely held by a dome comprising a receiver receptacle that selectively receives and holds the receiver. After the dome has been assembled, pulling on the electrical cable connected to the receiver will not dislodge the receiver from the dome.

Abstract: A computerized method is provided for designing a vent in a hearing aid housing shell based on an image of a patient's ear canal impression, and wherein a program is provided on a computer-readable medium. With the program, an image of a starter housing shell based on the image of the patient's ear canal impression is created which is longer than a final version of the housing shell to be created. A starter vent running from an inner canal end near the patient's ear drum to an outer end of the starter housing shell is placed inside the shell. Components are then placed substantially as deep as possible inside the starter shell but lying outside of the starter vent. Portions of the starter shell lying beyond where a faceplate is to be mounted are removed and the faceplate is mounted. The starter vent is then grown larger so that it fills substantially all space inside the shell without interfering with the components.

Abstract: A method (10) for fabricating a hearing aid using a self-contained hearing aid production laboratory employing three dimensional printing technology. The method (10) comprises the steps of conducting audiometric testing of an individual with a hearing impairment (12, 14); selecting and customizing a product design for the hearing aid to be produced (16, 18); producing the selected and customized hearing aid (20, 22, 24); and performing final adjustments to the produced hearing aid (26, 28).

Abstract: The capabilities of a helix hearing instrument may expanded with a behind-the-ear accessory module. The module accommodates additional batteries and a variety of accessory functions including an external volume control.

Abstract: Insertion of a wax guard with a bridge into the receiver tube of a hearing instrument may be accomplished with a tool that grasps the wax guard securely, inserts the wax guard into the tube, and then slides off of the wax guard, leaving the wax guard within the tube.

Abstract: A space-saving electrical contact assembly for a hearing instrument faceplate can be fashioned by physically conforming the configuration of individual contacts to the battery and the battery door in the faceplate. By providing each contact of the assembly with an interconnected terminal, the wiring of the assembly is reduced.

Abstract: In a method for automating design of a locking mechanism for a hearing instrument, a computerized 3D file of an ear impression shell surface is provided based on a 3D scan of a 3D ear impression of a patient's ear. The ear impression shell surface includes a locking surface comprising at least one of a helix or canal concha portion of the patient's ear. A 3D file is provided of a hearing aid shell. With a computer, the hearing aid shell is placed in a desired location in the ear impression shell surface where the hearing aid shell is to be locked in position. With the computer, a volume surface as a 3D file is created representing the locking mechanism by utilizing a profile of the ear impression shell surface to be used as the locking surface. The volume surface runs from the ear impression shell surface and along the profile of the locking surface.

Abstract: A portion of a hearing instrument housing or shell comprises one or more chambers having planar, conical, or convex walls. During assembly, this shape helps guide the receiver tube towards tip of the shell and the receiver tube hole. Additionally, it will reinforce the walls of the shell, decreasing the tendency of the shell to vibrate when the receiver is generating sound.

Abstract: In a system and method for open fitting hearing aid frequency response sound measurements, a test space is provided having located therein a sound source, a hearing aid with a microphone, and an open fit receiver. An acoustic shield is provided and within the acoustic shield an ear simulator coupler is provided having an ear extension attached thereto, the ear extension having mounted thereto at least a portion of the open fit receiver. A measurement unit receives sound signals from the ear simulator coupler.

Abstract: A pull string for a hearing instrument may be attached to an anchor positioned on the inside wall of the hearing instrument shell. Collision detection may be utilized to determine a location for the anchor and the pull string.

Abstract: A system and appertaining algorithm provide a cutting and shaping of the hearing aid shell using an Ellipsoidal Line Cut that increases the speed of detailing operations and enables a creation of more cosmetically appealing shells. A contour algorithm determines a projected contour on the bottom cut plane that corresponds in shape to a portion of the line cut plane contour, and a merger algorithm defines a line cut surface between the portion of the line cut plane contour and the projected contour. An elimination algorithm eliminates parts of the new hearing aid shell design that extend beyond boundaries defined by the original hearing aid shell design.

Abstract: In a method to create a hearing aid housing shell and a negative cast for a hearing aid to be fitted to a patient's ear canal, a 3D jet printer apparatus is provided able to build a 3D part by injecting both the soft material and a hard material with the soft material serving as a support for the hard material. The 3D file is input to the 3D jet printer apparatus to build the hearing aid shell with the hard material and the combined negative cast with the soft material. The negative cast is used to check a quality of the hearing aid shell and to add external features to the shell by fitting the shell into the negative cast.

Abstract: The low frequency efficiency of a hearing instrument receiver can be improved by increasing the unoccupied rear volume. The receiver may be configured with one or more motor and diaphragm assemblies. The receiver may also be fabricated using multiple, conventional receivers with an added housing to create the increased, unoccupied rear volume.

Abstract: A receiver tube for a hearing instrument may be securely affixed to the instruments receiver with a retaining clamp. Such an arrangement facilitates assembly and repair, and provides a positive means for the securing the receiver tube.

Abstract: A small hearing aid is provided which fits completely in an ear canal of a user wherein a shell as an outer housing of the hearing aid is shaped to closely surround components of the hearing aid to provide a gap between the hearing canal inner walls and the shell to allow flow of air when the hearing aid is mounted in the ear by a mounting element connected to the shell. The mounting element is provided with at least one aperture to allow the air flow. In a fabricating method, an image of the shell is shrunk to closely surround the hearing aid components while maintaining a shape of the ear canal to assure a custom fit.

Abstract: A hearing aid with a microphone for receiving acoustic signals and converting them to electrical signals, electronic circuitry for processing the electrical signals, and a speaker for converting the processed electrical signals into acoustic signals, has a shell that encases at least portions of the microphone, the electronic circuitry, and the speaker, the shell further encasing an inside volume. The hearing aid further has a vent that provides an opening between the inside volume and a region external to the hearing aid. A flexible membrane is provided that covers an opening of the vent and an acoustic resistor that contacts the flexible membrane. The membrane helps prevent wax fumes from entering the inside volume, and the acoustic resistor helps to reduce distortion in the frequency response of the hearing aid.

Abstract: The present invention relates generally to a method for assembling a hearing aid device, comprised of providing a software system that determines a position for a virtual receiver and a position for at least one component of a virtual faceplate inside a hearing aid shell. The present invention also includes utilizing guides to replicate the position for the receiver and the position for at least one component of the faceplate during construction of the shell, and providing the software system to verify that the receiver and one or more components will not collide with the faceplate and guides. The present invention is further comprised of providing the software system to merge the shell with the guides.

Abstract: The manufacture of a hearing instrument having a hard inner shell and a softer outer covering, for insertion into the ear canal of the user, may be accomplished using rapid manufacturing and prototyping techniques. Starting with a digital model of the ear canal, a mold for the softer outer covering may be fabricated using a process such as stereo lithography.

Abstract: The compliance of a receiver tube for a hearing instrument may be enhanced by fabricating it as a composite assembly of a tube and a compliant insulator positioned between the tube and the receiver. The material of the insulator is selected such that it has a greater compliance than that of the tube.