Silicon Insert Injection Cast IEMs/Earbuds

I often fall asleep wearing earbuds, only to wake up with sore ears and find them scattered somewhere around my bedroom. This frustration motivated me to design custom in-ear monitors (IEMs) with a soft silicone outer shell that prioritizes comfort during sleep, provides high levels of noise isolation, and stays securely in place throughout the night.

Solution:
-Modeled an insert that accommodates a Knowles balanced armature driver, acoustic tubing, and a 2-pin connecter.
-From a 3D scan of my right ear, modeled a silicon outer shell that fits perfectly inside my ear
-Created molds which include alignment and sealing features, an injection port, and venting
-Soldered drivers to 2 pin connector and installed in insert
-Sealed insert using CA glue and UV curing resin
-Injected 2-part platinum cure silicon around insert
-After demolding, installed audio filters to remove out abrasive high frequency band