The Naval Air Warfare Center Aircraft Division (NAWCAD) has partnered with Navy Dentistry to modernize hearing protection for sailors and warfighters using digital ear-scanning and 3D printing technology. Recognizing that noise-induced hearing loss remains the Defense Department’s most common injury, NAWCAD’s Auditory Performance Lab, led by LCDR Kyle Shepard, has developed a faster, safer, and more precise way to create custom-fit hearing protection. Traditional silicone-impression methods are slow, inconsistent, and can cause discomfort or anatomical complications. In contrast, digital ear-scanning captures the exact geometry of a sailor’s ear canal using a small probe, eliminating the risk of physical warping and reducing production time by over 50 percent. This innovation—aligned with the Navy’s existing 3D printing infrastructure in dental medicine—allows commands to manufacture custom earplugs on-site, ensuring improved comfort, reliability, and protection. Early fleet testing shows overwhelming support from sailors and Marines, who report superior fit, comfort, and communication clarity compared with foam or standard plugs. The program’s ultimate goal is to equip every service member with custom hearing protection made from precise 3D ear scans, enhancing safety, readiness, and mission performance across the Department of Defense.  

The U.S. Navy is modernizing its approach to hearing protection to combat one of the military’s most reported disabilities—noise-induced hearing loss and tinnitus. Traditional foam earplugs and earmuffs have proven inconsistent and uncomfortable, prompting the Naval Air Warfare Center Aircraft Division (NAWCAD) to develop a digital solution. Led by Lt. Cmdr. Kyle Shepard, NAWCAD has introduced a new system using digital ear scanning and 3D printing to create custom-fitted hearing protection for every sailor. The process replaces the outdated silicone mold method with a safer, faster, and more precise scan, cutting production time by more than 50%. Sailors report improved comfort, better fit, and higher daily-use compliance. The Navy envisions a future where sailors could be fitted for hearing protection as early as uniform issue, with 3D printers onboard ships and at bases enabling on-demand manufacturing. This innovation not only improves safety and readiness but also positions the Navy as a leader in next-generation hearing protection for joint military services.

The U.S. Senate recently advanced its Fiscal Year 2026 Defense Appropriations bill, providing an additional $7.5 million in Army Research, Development, Test, and Evaluation funding to improve existing hearing protection and communications solutions. “We are honored to partner with the U.S. Army to revolutionize military hearing protection for our warfighters,” said Sam Kellett, Jr., CEO of Aware. “Hearing loss is the number one service-connected disability, and Aware is delivering solutions to prevent it — setting a new standard for protection and performance. Because every ear is different, our 3D ear scanner delivers precision-built protection and communications for mission-critical environments, and our Hearable with continuous multimodal monitoring represents the next generation of in-ear innovation.”  

The insights from NAWCADPAX/TR-2006/73 perfectly align with Aware Defense's mission. Aware’s 3D Ear Scanning technology eliminates the fit and comfort barriers identified in the Navy study, ensuring full-shift wearability and consistent protection. By integrating biometric monitoring and in-ear communication, Aware advances the exact capabilities the Navy report called for—technology that allows users to protect hearing without sacrificing awareness or mission performance.

Over a five-year period, Aware Industrial’s 3D-scanned custom hearing protection demonstrated a proven 360%+ ROI through reduced waste, fewer compensation claims, and improved compliance.

The U.S. Navy’s research teams are using 3D ear-scanning and additive manufacturing to modernize hearing protection for sailors exposed to extreme noise on aircraft carriers and flight lines. Developed by the Naval Air Warfare Center Aircraft Division (NAWCAD), this breakthrough replaces traditional silicone ear molds with precise digital scans that capture the full ear canal geometry. The result is custom-fit earplugs that provide superior acoustic sealing, all-day comfort, and consistent protection against damaging decibel levels. By integrating 3D printing with digital imaging, the Navy can produce hearing protection devices in-house, cutting delivery times in half and improving readiness across aviation, shipboard, and expeditionary environments. This innovation marks a major advancement in warfighter safety and performance, setting a new benchmark for the future of military hearing conservation.

Human ears continue to grow slowly throughout life, mainly in the outer ear lobe, while the ear canal and concha remain the same size and shape. This means a single 3D ear scan provides a lifetime-accurate fit for custom hearing protection.

Independent Study Validating in Bioengineering – 3D ear scanning captures the full geometry of the ear canal—including the second bend—with unmatched accuracy and comfort. Aware’s eFit 3D Scanner delivers a precision acoustic seal and consistent fit, outperforming traditional silicone impressions in safety, speed, and field-proven reliability.

The world’s only patented, FDA-cleared, non-contact ear scanner—a breakthrough in precision and safety unmatched by traditional methods. In under two minutes, eFit delivers exact ear canal mapping without foam or silicone, ensuring maximum comfort, zero risk of injury, and a flawless custom fit. Natus licensed our 3D ear scanning technology, branded as Otoscan, which has been adopted by the hearing aid industry and is trusted by audiologists worldwide—proven in clinical use.

The Center for Disease Control (CDC) estimates that 22 million workers are exposed to potentially damaging noise at work each year. Whether you work at a sports venue, entertainment establishment, on a tarmac, or operate a jackhammer—hearing loss is preventable.

OSHA’s Hearing Conservation guide outlines employer responsibilities for preventing occupational hearing loss through monitoring, training, and proper protection under 29 CFR 1910.95. It emphasizes that hearing damage is permanent—but entirely preventable with an effective conservation program.

NIOSH emphasizes that occupational hearing loss is one of the most common—and preventable—workplace injuries. Effective hearing conservation programs combining noise control, protective equipment, and monitoring are essential to safeguard workers in high-noise industries.

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. T

Honeywell’s Noise-Induced Hearing Loss at Work white paper explains how prolonged noise exposure above 85 dBA causes irreversible damage and financial loss. It outlines proven strategies for Safety VPs to build effective, compliant hearing conservation programs that protect workers and reduce risk.

The NHCA outlines criteria for determining and recording work-related hearing loss on the OSHA 300 Log, emphasizing accurate reporting, ethical review, and employee follow-up. These guidelines help ensure hearing conservation programs meet both regulatory and preventive best practices.

Medical Futurist Article: Headphones are rapidly evolving from entertainment devices into health tools capable of tracking vital signs, monitoring hearing, and even capturing medical-grade data. With companies like Apple and Aware leading the charge, these “hearables” are transforming accessibility and redefining how we measure and manage personal health.

Aware Custom Biometric Wearables announces the publication in the Journal of Neural Engineering of an independent study validating its groundbreaking Ear-EEG, a non-invasive in-ear solution for long-term electroencephalogram (EEG) brain monitoring. The Aware Hearable, enabled by Aware’s patented 3D ear scanner, offers a custom-fit earbud designed for the ambulatory recording of brain activities with unprecedented precision.

Aware Custom Biometric Wearables has been named one of the Top 8 Wearable Tech Innovators for 2025 by the Innovation World Cup® and will present at the WT | Wearable Technologies Conference USA in Mountain View, California on September 16, 2025. This honor recognizes Aware's groundbreaking work in custom in-ear devices that combine hearing protection, enhanced communication, and continuous biometric monitoring—transforming the human ear into a platform for health and human performance.