OC GmbH and CADdent 3D print patient-specific earmolds

OC GmbH, a Swiss premium manufacturer of otoplastics and hearing protection, and CADdent, a German service provider, have achieved a breakthrough in 3D printed patient-specific earmold (otoplastics) production. Utilizing Lithoz’s LCM technology – a leading system for high-performance ceramic 3D printing – the team serially produces earmoulds made from ATZ (alumina-toughened zirconia) that are ultra-precise in fit, acoustically neutral, and biocompatible.

Further expanding the CeraFab printer’s track record of successfully scaling high-end ceramic medical devices to an industrial level, the otoplastics’ commercialization again proves the growing significance of LCM printers for innovation in the MedTech industry. Meeting the stringent requirements of medical OEMs, the project marks yet another go-to-market milestone for custom-fit ceramic devices.

Using the CeraFab S65 Medical, CADdent produces ATZ earmoulds with wall thicknesses below 1 mm and dimensional tolerances of less than ±50 µm, all the while maintaining the delicate inner channels necessary for optimal sound transmission. Thanks to stress-free sintering, the parts could be manufactured without support structures while ensuring structural stability, even in fragile geometries. Furthermore, the scalability of the process for small-batch industrial production is demonstrated by the fact that up to 15 earmoulds can be produced per build platform, resulting in a low threshold for innovation.

“These technical achievements demonstrate the distinct advantages that ceramics offer for otoplastics. Unlike polymers or titanium, ceramic earmoulds offer long-term biocompatibility alongside superior durability and wear resistance. ATZ’s acoustic neutrality ensures uncompromised sound quality, and the material’s aesthetic properties allow for customizable, high-value designs,” said Jurij Belik, CEO of OC GmbH.

This innovation combines the highest possible acoustic precision guaranteed by ATZ as the material of choice, the best possible hygienic behavior provided by biocompatible ceramics in general, individually optimized wearing comfort given by the design freedom in 3D, and economically viable production at an industrial scale ensured by the exact repeatability secured by LCM printers.