First of all.. ew.. Ear Mold?
Actually it’s not what you think, and technically it’s an impression with the ear itself being the mold. Which would be a good topic for later discussion.
So here’s the project.. Create a pocket sized container for a pair of custom fit hearing protection plugs. It needs to keep them together, yet with separate compartments for sanitary purposes. Small and light weight, fitting easily in a shirt pocket.
Quick measurement allowing for finger clearance yielded for each pocket:
- 1.000″ wide
- 1.500″ long
- 0.625″ deep
To start off with, you really only need to design half a box and mirror it over. Here we see the exterior plan form with edges rounded for comfort.
Then create lines set 0.0625″ (1/16th) in from the exterior plan to create the well and side walls. From that generate an extrusion 0.1250″ (1/8th) shorter than the main box, and subtract leaving the final well.
Take the formed box structure and mirror it along the center of the separating wall. The result will be the final box form with the required two wells.
Add the mirrored sides together leaving the final product ready for production.
Off to the printer we go.
Now that we have a box that fits the items, it’s on to the lid. Nothing truly special here, just a simple 0.0625″ (1/16th) cap with tangs to grip the interior wall surfaces.
Now that all our pieces are off the printer, time to check for fit and last minute changes.
Cap fits snug with the tangs keeping a firm grip. Subjected container to shaking while holding the sides and facing down, simulating shocks with ear molds impacting the cap interior. Cap did not fail under load.
Designed, printed, tested and ready for delivery in just under two hours. No surface treatments added due to possible reactivity and health concerns with ear mold contact. Client satisfied with results and will report back with any issues or desired changes.