Brainwavz Introduces Latest 3D Printed Earbud Model, the Koel

Earlier this year, Brainwavz became the latest company to adopt 3D printing for its earbuds. The company started by releasing the B400 model, which featured an innovative shape only made possible by 3D printing. They’re a true example of how far earphones really have come over the years – from the large, clunky, over-the-ear models that weighed about 10 pounds, to the flimsy foam-covered wire devices of the Walkman era, to the invention of the earbud. While earbuds were exciting, however, they weren’t without their own problems. They could be uncomfortable wedged in the ear, and the cheaper ones had an annoying tendency to fall out frequently.

Brainwavz addressed these issues with its 3D printed earbuds.  Designed for comfort and security, the carefully shaped buds not only stay in place but are meant to be hardly felt. Now Brainwavz has come out with a new 3D printed earbud model, the Koel. Like their predecessors, the Koel buds are lightweight and ergonomically designed for what the company describes as a “true fit-and-forget experience.”

The Koel earbuds also offer a balanced sound quality that has been described in glowing terms by reviewers. As a child of the 90s, I have a hard time believing the sound quality that is offered by good earphones today. I grew up with the cheap, tinny-sounding earphones that came with Walkmans (Walkmen?) and later Discmans. Not only was the sound bad, they would slide off constantly, and the soft foam covering them for “comfort” would easily tear, leaving exposed metal.

Koel earbuds are designed not to go anywhere – their 3D printed design makes for a snug fit, and over-the-ear cables prevent movement of any kind. They’re made to make you feel as though you’re right in the room with your favorite musical artists, without an earbud sliding around and jabbing you in the ear to remind you of its presence. The earbuds come with six sets of silicone ear tips so that you can find your own perfect fit, as well as foam tips and a shirt clip to keep the cable securely in place.

Brainwavz has come out with a large number of earbud models quite quickly, and 3D printing is largely to thank for the company’s productivity. The technology allows for fast design iteration in addition to the creation of shapes that would not be possible by other manufacturing means such as injection molding, as the company proudly emphasizes. Several other companies have turned to 3D printing to create their earbud shells, and it’s not hard to see this industry as being one that eventually embraces additive manufacturing as its standard means of production.

Brainwavz Koel earbuds are currently priced at $55.60, marked down from $69.50. The company offers 24 months warranty and free shipping to many locations around the world. You can learn more about Koel earbuds here.

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3D Printed Wireless Earbuds Help Enhance Hearing and Reduce Stigma Around Traditional Hearing Aids

Manchester Metropolitan University graduate Elen Parry, a current Industrial Digitalisation masters student at the university and an International Autodesk Student Ambassador for the UK, is focused on using “Human-Centred Design methods” to reduce exclusion against people. Her current project is a 3D printed wireless earbud concept, aimed at helping people with hearing disabilities fight the stigma around traditional hearing aids, while enhancing their hearing at the same time.

Parry’s HeX earbuds, which were chosen by the Design Council’s CEO Sarah Weir as the top pick for this year’s ‘New Designers’ event, are audio headphones that can also be used as an advanced hearing device. The concept calls for the use of an advanced chip, which would receive and process sound signals and be able to differentiate and control what you actually want to hear and normal background noise. Users could decrease or increase the volume of their environment, which could help extend their ability to hear while at the same time protecting them against hearing loss.

Thanks to technology like 3D printing and connected manufacturing systems, it’s now possible to produce devices like hearing aids and earbuds, and combined products like HeX, on a large scale.

“My mission is to encourage social inclusion through my designs, to create improved situations for everyone. The driving principle behind creating HeX earbuds was to create a hearing device that is for everyone – whether you live with hearing loss or perfect hearing,” said Parry.

“People with disabilities often feel excluded and conspicuous because of their medical devices, so I want to transform hearing aids into a desirable wearable tech product that gives people enhanced hearing, style and confidence – something that anyone might want to wear.

“3D printing enables us to manufacture them quickly and relatively simply, so HeX earbuds could be easily produced for a mass audience.”

The HeX earbuds would be made out of silicone, with single to three flange protection and medical-grade titanium casing, and able to be personalized and 3D printed to exactly fit any ear size or shape. The product’s hexagonal shape offers a more natural, multi-directional hearing experience, which would make it possible for users to hear and process a multitude of different sounds. The idea is for the hearing aid earbuds to also provide the latest connective technologies, so that no matter a person’s hearing ability or lack thereof, HeX is still a sought after product in the mass market.

“It was my intention to design an accessible hearing aid that removes social barriers and can enhance human ability, making it desirable to a wider range of people,” Parry wrote on her site.

For instance, HeX users could connect with other devices in order to easily complete tasks like streaming music or answering the phone while out and about through the use of embedded Bluetooth, infrared, and motion technologies.

Additional technologies Parry hopes to incorporate into HeX include rechargeable graphene batteries, along with dual connectivity strips for fast charging.

A 3D printed prototype of Parry’s HeX earbud concept has already been produced at the university’s advanced 3D printing and digital manufacturing hub Print City, which is open to both industry and researchers.

“This is one of many examples of how additive manufacturing and out-of-the box thinking by Elen disrupts the current design of medical devices,” said Professor Craig Banks, the academic lead of Print City.

Few industries have been affected quite as much by 3D printing as the hearing aid manufacturing industry, which switched entirely to 3D printing several years ago after Phonak, owned by Sonova, began using the technology to produce its hearing aids. The global company was seeing such success with 3D printing that the rest of the industry noticed, and quickly followed suit. Not long after, other production methods in the hearing aid world were basically wiped out by 3D printing.

With innovative products like the HeX earbuds, and makers like Parry who are conscious of and fight back against the social issues of the day, we’re truly seeing what 3D printing is capable of helping us create. I bet we haven’t even cracked the surface yet.

[Source: Design Products & Applications / Images: Elen Parry]

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