Abstract

An earplug which conforms to the concha of the ear and extends into the ear canal. The construction consists of a flexible outer skin with at least one filler material, preferably two or more materials of varying hardness, to form an essentially solid structure except for sound channels, or electronics packages, or other devices, parts and cavities that may be located within the flexible skin. The flexible skin can be fabricated using a rapid-prototyping printing process.