US Patent 7864972 Customized in-ear interface for acoustic equipment and method

An in-ear interface comprises an ear module shaped to be received in an ear canal. The ear module has a core defining a sound bore for enabling sound transmittance into the ear canal. A sheath covers a portion of an outer surface of the core so as to define an expandable space between the sheath and the core. An opening is defined in the core communicating with the expandable space whereby the expandable space is adapted to receive a settable compound to expand the ear module to the shape of the ear canal. An insert is secured to the ear module and has a slender portion received at least partially in the sound bore to generally maintain a shape of the sound bore during reception and curing of the settable compound in the expandable space.