Method of forming an earplug by laser ablation and an earplug formed thereby

1. A method of forming an earplug, comprising:

removing a material by laser ablation;

wherein said removing the material comprises forming a cavity in the earplug;

wherein said removing the material further comprises forming the cavity in a first end of a sound attenuating portion of the earplug, the cavity having a cylindrical shape and extending into the sound attenuating portion, along a longitudinal axis of the sound attenuating portion, toward a second end of the sound attenuating portion opposite the first end;

where the method further comprises inserting and retaining at least one of a cord, a stem, and a detectable insert in the cavity.

2. A method of forming an earplug, comprising:

removing a material by laser ablation;

wherein said removing the material comprises forming a cavity in the earplug;

wherein said removing the material further comprises forming the cavity in a first end of a stem portion of the earplug, the cavity having a cylindrical shape and extending into a body of the stem, along a longitudinal axis of the stem, toward a second end of the stem opposite the first end, the earplug including a sound attenuating element attached to the stem at the second end.

3. The method of claim 2 , further comprising inserting and retaining at least one of a cord and a detectable insert in the cavity.

4. A method of forming an earplug, comprising:

removing a material by laser ablation;

wherein said removing the material comprises forming a channel through at least a portion of the earplug;

wherein said removing the material further comprises forming the channel in a stem portion of the earplug, the channel having a first opening at a first end of the stem and a second opening at a second end of the stem opposite the first end, the channel traversing a longitudinal length of the stem from the first opening to the second opening, the earplug including a sound attenuating element attached to the stem at the second end.

5. A method of forming an earplug, comprising:

positioning the earplug proximate a laser;

identifying a portion of the earplug to be ablated;

activating the laser so as to direct an emitted laser light toward the portion to be ablated; and

ablating the portion to be ablated;

wherein the portion to be ablated comprises a portion of the earplug corresponding to a channel to be formed through at least a portion of the earplug, and wherein said ablating the portion forms the channel;

wherein said channel is formed in a sound attenuating portion of the earplug and said positioning the earplug comprises disposing the sound attenuating portion in a fixture, compressing the sound attenuating portion in the fixture, maintaining the sound attenuating portion under compression, and positioning the fixture proximate the laser.

6. A method of forming an earplug, comprising:

positioning the earplug proximate a laser;

identifying a portion of the earplug to be ablated;

activating the laser so as to direct an emitted laser light toward the portion to be ablated; and

ablating the portion to be ablated;

wherein the portion to be ablated comprises a portion of the earplug corresponding to a cavity to be formed in the earplug, and wherein said ablating the portion forms the cavity; the method further comprising receiving and retaining at least one of a cord, a stem component, and a detectable insert in the cavity.