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To accommodate the variation in ear canal shapes and sizes, I used 3D scan data to created custom 3D printed earplugs designed to fit users perfectly. The prototypes were designed in Autodesk Fusion 360, converted into a printable mesh in Cura, then printed using PrintrBots. The prototypes were printed in PLA (print time 20-25 min), and the final products would be memory foam with a thin outer layer of silicone, as both materials are available as 3D printer filaments, attenuate sound well and are comfortable for the wearer.
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