Hearing assistance device and method of forming same

1. A hearing assistance device to provide sound to an ear of a patient, the device comprising:

a housing adapted to be worn on or behind the ear;

hearing assistance components enclosed in the housing;

an earmold adapted to be worn in the ear;

a sound tube adapted to transmit sound from the housing to the earmold, wherein the sound tube comprises an inner diameter that is equal to at least 0.5 mm and no greater than 5 mm; and

an earhook adapted to connect the housing to the sound tube;

wherein the earmold and the sound tube are printed three dimensionally (3D) as one piece that is custom fit for the patient using a computer-aided design software (CAD) model, wherein a first end of the sound tube is integral with the earmold.

2. The device of claim 1 , wherein the earmold and the sound tube comprise silicone.

3. The device of claim 1 , further comprising a coating disposed on the earmold and the sound tube.

4. The device of claim 1 , wherein the earhook is integral with a second end of the sound tube.

5. The device of claim 1 , further comprising an extension tube connecting the sound tube to the earhook.

6. The device of claim 1 , wherein the hearing assistance components comprise at least one of a processor, a microphone, a receiver, a power source, and an antenna.

7. The device of claim 1 , wherein the earhook is integral with the sound tube.

8. A method of forming a hearing assistance device, comprising:

forming a three-dimensional model of an ear cavity of a patient;

forming a three-dimensional model of an earmold based upon the three-dimensional model of the ear cavity;

forming a three-dimensional model of a sound tube that is integral with the three dimensional model of the earmold, wherein the three-dimensional model of the sound tube is aligned with a sound hole of the three-dimensional model of the earmold; and

3D printing an earmold and a sound tube from the three-dimensional models of the earmold and sound tube, wherein a first end of the sound tube is integral with the earmold, wherein the sound tube comprises an inner diameter that is equal to at least 0.5 mm and no greater than 5 mm.

9. The method of claim 8 , wherein 3D printing the earmold and the sound tube comprises stereolithographically printing the earmold and the sound tube.

10. The method of claim 8 , wherein 3D printing the earmold and the sound tube comprises printing the earmold and the sound tube utilizing direct light processing.

11. The method of claim 8 , wherein 3D printing the earmold and the sound tube comprises:

3D printing the earmold with a first composition; and

3D printing the sound tube onto the earmold with a second composition.

12. The method of claim 11 , wherein a hardness value of the first composition is greater than a hardness value of the second composition.

13. The method of claim 8 , wherein 3D printing the earmold and the sound tube comprises:

printing a hollow cast that comprises an earmold portion and a sound tube portion integral with the earmold portion;

disposing a composition within the hollow cast;

curing the composition to form the earmold and the sound tube; and

removing the hollow cast from the earmold and the sound tube.

14. The method of claim 8 , further comprising forming an earhook comprising a first end and a second end, wherein the second end of the earhook is integral with a second end of the sound tube.

15. The method of claim 14 , further comprising connecting the first end of the earhook to a housing of a hearing assistance device.

16. The method of claim 14 , wherein forming the earhook comprises:

forming a three-dimensional model of the earhook that is integral with the three-dimensional model of the sound tube; and

forming the earhook from the three-dimensional model of the earhook.

17. An earpiece comprising:

an earmold comprising a sound hole;

a sound tube comprising an inner diameter and a first end that is integral with the earmold such that the sound tube is acoustically connected to the sound hole of the earmold; and

an earhook that is integral with a second end of the sound tube;

wherein the earmold, sound tube, and earhook are printed three dimensionally (3D) as one piece that is custom fit for the patient using a computer-aided design software (CAD) model.

18. The earpiece of claim 17 , wherein the earmold, sound tube, and earhook comprise silicone.

19. The earpiece of claim 17 , wherein the sound tube comprises an inner diameter that is equal to at least 0.5 mm and no greater than 5 mm.

20. The earpiece of claim 17 , wherein the sound tube and the earhook comprise a material that is different from a material of the earmold.