Custom 3D-Printed Earplugs: The Smart Way to Protect Hearing at Work

In noisy work environments, hearing protection is essential - not just for compliance, but to safeguard the long-term health and wellbeing of employees. At TAC Healthcare, we use a cutting-edge solution for industrial hearing protection: custom reusable earplugs created using 3D optical laser scanning technology.

Unlike traditional disposable earplugs, which don’t always fit properly and generate unnecessary waste, our service provides a comfortable, effective, and sustainable alternative.

Why Choose 3D-Scanned Custom Earplugs?

1. Precision Fit for Maximum Protection

Using advanced 3D optical laser technology, we create a digital model of each individual’s ear. This ensures the earplugs are an exact fit, providing the full level of protection required. With disposables, workers often compromise on fit - meaning protection levels vary, leaving hearing at risk.

2. No Chemicals, No Waste

The scanning process is 100% clean and waste-free. Unlike older moulding techniques that required silicone impressions, this method is safe, quick, and environmentally friendly.

3. Reusable & Sustainable

Made from medical-grade antibacterial silicone, the earplugs are reusable and long-lasting. This reduces reliance on single-use plastics, helping companies meet their environmental, social, and governance (ESG) goals.

4. Cost-Effective Investment

Disposable earplugs are single-use, meaning staff often need multiple pairs per day. Custom earplugs, on the other hand, are durable and reusable, providing consistent, reliable protection for your workforce making them a cost effective long term solution.

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How the Process Works?

• Appointment: Each scan takes approximately 15–20 minutes, including a demonstration on how to care for and use the earplugs.
• 3D Scan: The scan itself takes around 10 minutes (depending on ear anatomy).
• Production: The moulds are 3D printed in the UK and shipped within 1–2 weeks.
• Personalisation: Before scanning, you select the appropriate filter strength (depending on the exposure levels and industry). We can recommend what strength each employee needs depending on their job responsibilities.

Practical Considerations

• Clean Ears Required: Excessive or compacted wax prevents an effective fit. Staff should arrive with clean ears.
• Longevity: Ear shape changes over time, so it is recommended to rescan your ears at least every 5 years.
• Easy Replacement: If plugs are lost, no new scan is needed - we can simply reprint them.

Additional Benefits

• Reliable Protection: Custom earplugs don’t suffer from the fit issues common with disposable ones. They also maintain their effectiveness even when other PPE, such as safety glasses, helmets, or face shields, is worn, ensuring consistent hearing protection throughout the workday.
• Environmental Impact: Companies switching to custom earplugs significantly cut down on plastic waste - particularly beneficial in offshore environments where hundreds of disposable plugs are used daily.

Book a Demonstration

We can provide a demonstration of the 3D scanning system to show just how quick, safe, and effective the process is.

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📩 Contact our Business Development team at businessdevelopment@tachealthcare.com to arrange a demo or discuss your workforce’s hearing protection needs.