Custom Hearing Aids (e.g., Siemens, Phonak): 3D printed hearing aids were among the first mass-customized medical devices. Using digital ear scans, companies like Phonak create precise 3D models of ear canals, then print shells from biocompatible acrylics. This ensures a perfect fit, improving comfort and sound quality while reducing feedback. The automated process replaced manual casting, enabling rapid, high-volume production of millions of units annually. Each device is unique, showcasing true mass customization. 3D printing allows for smaller, more discreet designs and faster turnaround. This application highlights additive manufacturing’s role in scalable, patient-specific healthcare, improving accessibility and quality of life for hearing-impaired individuals while setting a benchmark for digital transformation in medical device manufacturing.
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