How are custom in-ear monitors made?

If you don’t already know, custom in-ear monitors (CIEMs) are a type of earphone, but with two major distinctions: they are custom molded to the users ears and are designed for high-definition audio reproduction. CIEMs were originally created to be used by professional musicians when performing live on stage, but were quickly adopted by audio engineers, audiophiles, and even gamers as well. If you’d like to learn more about CIEMs, check out our article What are custom in-ear monitors?.

At Maytak Audio, to ensure the best possible fit, all of our custom in-ear monitors are made via a digital manufacturing process. We utilize 3D scanning and printing to precisely recreate the intricate details and contours of the users’ ears in the final shells. The resulting fit from custom molded shells is significantly more secure while providing greater comfort and allowing for longer listening sessions.

A great pair of in-ear monitors begins with great a pair of ear impressions. If there are any significant defects or voids in the impressions, then they will need to be redone, as this will most likely have a negative impact on the fit and seal of the in-ear monitors. 

Getting the impressions made requires an appointment with a local audiologist. The process itself is fairly quick and easy, with the technician preparing and injecting a soft silicone material in the ear that hardens in just a few minutes. 

Once we receive the impressions, the production process can finally begin. We 3D scan the impressions and digitally process them to form the final shell before printing. This includes trimming any excess material, smoothing all rough edges, and making sure that all of the electronic components fit comfortably inside the shell.

Pro tip: check out our Ear Impression Guide on the How to Order page if you’re considering Custom IEMs.

Each IEM models’ drivers and crossover components are soldered and pre-assembled as “kits”. Each kit is carefully and thoroughly tested, and paired into stereo-matched sets before installation. 

Once the shells are 3D printed, they are washed to remove any excess resin and must be post processed before assembly. This process is done entirely by hand and includes the drilling of all venting and sound channels as well as the application of a gloss finish to the shells.

With the shells processed and electronics prepped, the assembly process can begin. Drivers and crossover components are carefully inserted, one at time, and secured into place. The earpieces are then tested to make sure that everything is functioning properly before applying the faceplates. 

To ensure that the earpieces don’t have any sharp edges, they are sanded smooth and prepped for a lacquer coating. We use an industry standard, biocompatible, high-gloss lacquer to create a finish that not only looks great, but allows for easier cleaning and insertion into the ear. 

The completed in-ear monitors are visually inspected for quality assurance and finally tested once again to ensure that they are working properly before being packaged and shipped. 

That’s it! What seems like a fairly straightforward process, actually takes an incredible amount of attention to detail and skilled craftsmanship. Is it worth it? You tell us. Check out our catalog and design your pair of IEMs.