Manufacturing process for a custom fit in-ear monitor utilizing a single piece driver module

摘要

A method of fabricating a custom-fit in-ear-monitor (IEM) is provided that utilizes a pre-tuned, single piece driver module to simplify fabrication and reduce cost while insuring that the performance of the IEM consistently meets the acoustic goals set for the device. During fabrication the driver module, the drivers coupled to the module's driver ports, and the crossover circuit are installed in a custom-fit IEM shell such that the module's acoustic output is aligned with the output surface of the IEM shell. After installing the device components within the IEM shell, the shell is sealed.

主权项

1. A method of fabricating a custom-fit in-ear-monitor (IEM), the method comprising the steps of:
obtaining an ear mold for a specific end user; scanning said ear mold to generate an ear mold data file; fabricating a custom-fit ear mold shell based on said ear mold, wherein said step of fabricating said custom-fit ear mold shell further comprises the step of manufacturing said custom-fit ear mold shell with a 3D printer; installing a plurality of drivers into a plurality of driver ports of a single piece driver module to form a driver assembly; electrically connecting said plurality of drivers to a crossover circuit, wherein said crossover circuit is configured to receive an electrical signal from an audio source that is external to said custom-fit IEM and to provide separate input signals to each of said plurality of drivers based on said electrical signal; installing said driver assembly and said crossover circuit into said custom-fit ear mold shell, wherein said step of installing said driver assembly further comprises the step of acoustically coupling at least one sound bore corresponding to an acoustic output member of said single piece driver module to an acoustic output surface of said custom-fit ear mold shell, wherein said at least one sound bore is acoustically coupled via a plurality of sound ducts within a body portion of said single piece driver module to said plurality of driver ports; and sealing said driver assembly into said custom-fit ear mold shell.