Project Type: Offshore Manufacturing Setup and New Product Development
Comfortable, well-fitted earphones are usually expensive, but even the expensive ones are not guaranteed to fit, which can cause them to fall out easily. Having your music or podcast continually interrupted by a wayward earphone is frustrating. From this stemmed our client’s idea: earphones molded to each customer – a perfect fit – at a reasonable cost. This would improve the listening experience by providing comfort while reducing ambient noise. The process is fairly simple, but it requires some DIY. The user puts on the earphones, mixes the molding, and press it over the earbuds. The mold then hardens, retaining the shape of the ear for optimal sound and comfort.
While the idea seemed simple enough, and the materials were easy enough to source, the headphone design presented a challenge. The earbud case required a special design with two holes which could support the mold once dried. The difficulty lay in the tooling – an expensive process which would mean a spike in the product’s price. This put our team’s negotiation skills to the test as we haggled with our suppliers for a more reasonable outcome.
After a period of careful communication with our supplier, we managed to come to agreement. The tooling was done only for the upper part of the earphone case. This allowed the product to retain its to keep its cost advantage and resulted in a high quality, customizable product that is, most importantly, affordable.
Vendor sourcing and qualification
Packaging and assembly
Tooling and Molding
In-ear custom mold
Output Mode: Stereo
Frequency: 20Hz – 20KHz
Mic Sensitivity: -42±5DB
Mic Impedance: 2.2K Ω
Stereo 3.5MM Jack
Cord Length: 1.2M
Noise Reduction: approximately 26DB