Abstract: A tailored active noise control design method is presented that provides for improved noise attenuation performance for each individual user and improved hearing protection in a specified noise field as a function of a specified metric indicative of a noise reduction objection. Characteristics of individual users, behavior of the associated passive hearing protection, and the external noise environment are all concurrently accounted for in an automatic method for designing an active controller that limits the exposed noise level for a specific individual. The controller manufacturing process and implementation may be performed in-situ for each individual automatically. The design method may also account for actuator limitations and can be applied equally well to any passive/active noise control devices including headphones and earplugs.