In this landmark study conducted by the U.S. Army Aeromedical Research Laboratory (USAARL), researchers evaluated the performance, comfort, and safety of custom hearing protection devices fabricated using digital 3D ear scanning technologies compared to traditional silicone ear impressions. The study tested six fabrication methods—including three digital scanning systems (Lantos™, 3Shape™, and Aware’s eFit™ Scanner)—to determine attenuation levels, fit consistency, and user comfort across 20 subjects.
Results confirmed that digital ear scanning methods, such as Aware’s eFit system, significantly improved comfort, efficiency, and safety over traditional ear impression techniques. The non-contact 3D scanning process eliminated risks associated with silicone impressions—including canal inflammation and tympanic membrane injury—while providing highly accurate ear canal mapping to within millimeters of the eardrum. Participants reported greater comfort and reduced irritation with digital methods, and researchers noted zero adverse events during scanning.
While traditional impressions produced slightly higher average attenuation, they were also rated the least comfortable and most invasive. The Army’s findings underscore that 3D scanning delivers clinically viable custom-fit hearing protection with faster turnaround, digital reproducibility, and substantially reduced medical risk.
The study concluded that digital scanning “provides potential advantages over traditional methods such as reduced logistical hurdles, reduced discomfort, and safer procedures,” validating 3D scanning as a feasible and preferred solution for military and industrial hearing protection applications