Custom in-ear monitors (CIEM) are a class of headphones most commonly used by professional musicians due to their incredible audio quality and equally high price. CIEMs are made by taking 3D scan data of a client's inner ear and then having a technician use various CAD programs to create an enclosure from this data manually. The finished model is 3D printed, components are hand fit inside the enclosures, and then custom caps are made for each headphone to seal it off.
The number of specialists involved in manufacturing results in a long lead time and high price for each set of custom monitors. We created an automated pipeline that generates all the CAD data without any specialists. Using a simple UI, a user selects the 3D scan data and the desired internal hardware configuration. Our software then runs a series of simulations to fit all components within the CIEM enclosure and create the necessary mounts for the driver hardware. This eliminates the need for a CAD operator and drastically decreases the assembly time of the output parts.