Modeling meistere task of a modeling meister is to deter-mine the optimal shape of the shell of the super compact hearing aid customized for an individual ear canal, and then to identify the design that will allow the necessary components to t inside the shell. On the computer screen before him are 3D images of the ear canal and the hearing aid current-ly being designed. If there’s a problem with the position of a component, it lights up in red on the screen. At first glance, this appears to be a straightforward process. But it’s actually quite complicated.“If our external ear canals were straight, we could have one compact design for all hearing aids. But that’s not the case. Especially in cases where the ear canal has a very narrow portion, the hearing aid can end up uncomfortably large unless the com-ponents are positioned just right. You might realize later that the hearing aid could have been made smaller just by reorienting a cer-tain component. But it’s not always easy to see that while you’re working on the piece. I believe this fundamental modeling skill is something you’re born with, not something you can learn from experience.”These are the words of Takayuki Masuda, one of only ve modeling meisters in Japan. He is a professional who has the skills to instantly retrieve an abundance of information from seeing a single earmold. He can determine the optimal design of the super compact hearing aid for an individual based on the diameter, direction, and cur-vature of the external ear canal. It takes him just 12 minutes to process one. Speed is another requirement for a meister.“Customized in-the-ear (ITE) hearing aids emerged in response to user demand for hearing aids that would be as unobtru-sive as possible. at’s why the basic policy for ITE hearing aids is to make them as small as possible. But in actual use, comfort and ease in handling are also important fac-tors. More specically, hearing aids have to be easy to put in while at the same time resisting falling out.”Due to the extremely small size of the Completely-In-Canal (Mini CIC) hearing aids, they have fewer protrusions than other hearing aids, making them more prone to falling out. So, if a customer has an external ear canal that makes it more likely that the hearing aid will slip out, we may have to add some length to the shell for a better hold. On the other hand, if the hearing aid ts too tightly, speech may sound muffled or be heard accompanied by echo eects. In this case, we have to shave o some of the shell to make room for air to pass. A meister has to recognize the characteristics and needs of individual customers based on the earmold and order form and make the necessary adjustments.“e modeling process for the Comple-tely-In-Canal (Mini CIC) poses these dicul-ties. I have to make a comprehensive judgement, taking into consideration many factors beyond size. at’s what makes it so interesting.”e demands on a modeling meister go beyond innate spatial cognition skills. Also required is an insatiable desire to explore the path to customer satisfaction.Takayuki MasudaChief of the Hearing Aid Shell Manufac-turing Section, Hearing Aid Manufac-turing Department, Rion Techno Co., Ltd. Before the introduction of the Yumeji Kobo automated shell production sys-tem, he had acquired experience in ana-log hearing aid manufacturing and was an expert in the assembly of hearing aids. He has been a modeling meister since February 2014.An architect of super compact hearing aids with excellent spatial cognition and an inquisitive mindcrasmanship remains indispensableHow much can you imagine from an earmold?The meister determines the size and shape of the hearing aid based on the earmolds provided, taking into consideration the difference between the earmold and the actual ear, and even the specific skills of the sales staff who took the earmolds.Harmonizing the digital and the real worldWhile working with the digital data, the meister integrates the information obtained from the actual earmolds to create an image of the shape that will result in a comfortable fit. This requires laser focus.A 3D scanner scans the earmolds taken at hearing aid retailers from around Japan. It takes about 30 seconds to accurately reproduce the scanned 3D data.3D scanningFor the Completely-In-Canal (Mini CIC), a modeling meister uses a CAD system to determine the optimal shape and size of the shell and component placement for each individual customer.ModelingA special 3D printer is used to mold the shell based on the modeling data. This piece of equipment is constantly monitored under strictly controlled temperature and humidity conditions.Molding using a 3D printerProduction process for custom-made hearing aids (selected steps in the manufacturing process)Meister
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