Abstract: 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.

Abstract: An ear-wearable electronic device comprises a shell having a uniquely-shaped outer surface that corresponds uniquely to an ear geometry of a wearer of the device. The shell comprises a window through a proximal portion of the shell and positioned at ear canal tissue when the device is deployed in the wearer's ear. An optical sensor, such as a photoplethysmograph (PPG) sensor, is disposed in the window. A biasing member has a uniquely-shaped outer surface that corresponds uniquely to a geometry of at least a portion of a pinna of the wearer's ear. The biasing member is configured to generate a biasing force sufficient to maintain static positioning of the optical sensor relative to the ear canal tissue during wearer body and jaw movement.

Abstract: An ear-wearable electronic device includes a shell having a uniquely-shaped outer surface that corresponds uniquely to an ear geometry of a user of the ear-wearable device. The device includes an elongated sensor assembly. A mounting bridge is formed integrally with the shell and has a mounting surface that supports the elongated sensor assembly. An elongated void is in the shell that exposes the mounting surface of the mounting bridge. The shell includes an access void that extends from the inner surface to the outer surface of the shell near a first end of the mounting bridge. The access void is larger than a minor cross section of the elongated sensor assembly such that the elongated sensor assembly is able to pass through the access void and be held against the mounting surface.

Abstract: An ear-wearable electronic device includes a shell with a cable retention slot. The cable entrance slot has an interior end and an exterior end. A bend surface extends from the exterior end of the cable retention slot to an exterior surface of the shell. The bend surface aligned with a crux of a user’s ear when the ear-wearable device is installed in an ear of the user’s ear. The shell may include a uniquely-shaped outer surface that corresponds uniquely to an ear geometry of the user of the ear-wearable device.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.