The human ear canal exhibits significant variability in size, length, cross-section, and curvature. Successfully embedding sensors deep within both ears, ensuring they remain in place overnight while maintaining optimal pressure without causing discomfort or disrupting sleep, presents a sophisticated ergonomic challenge.

Key questions we addressed included:

• How can we fit the electronics into every ear canal to achieve perfect contact and pressure?

• How can we ensure the sensors remain securely in place throughout the night without disrupting sleep?

• How can we design this for home use, allowing individuals to maintain their dignity while wearing it?

As with all ergonomic challenges, this required extensive prototyping and testing with real people. Our team developed hundreds of prototypes and tested them with dozens of participants. To expedite development and facilitate weekly iterations and feedback loops, we designed and manufactured our own high-precision molds and cast intricate silicone components