Sennheiser is a veteran audio brand that has produced some of the best headphones and best wireless earbuds, but when it comes to customizing the fit of its in-ear buds, it currently offers only a few different tip sizes in the box. [Sennheiser's Ambeo division has partnered with Formlabs, a 3D printing company, to print custom-fitting earbud tips If you're struggling to get a comfortable fit with earbuds like the AirPods Pro, custom earbuds are affordable and Possibly available.

Under the plan, buyers would use their phone's camera to create a scan of their ears, which would then be sent to Sennheiser. The company then uses Form 3B, an industrial 3D printer "optimized for biocompatible materials," to print a set of ear tips that fit the person's ears perfectly.

While it is already possible to create custom-made earbuds, it is an expensive luxury and far from widespread. Some headphone manufacturers are also experimenting with "moldable earbuds" made of flexible materials that fit the ear, but even then they often do not provide the exact fit of a measured, completely custom design.

Sennheiser is looking to 3D printing as a solution to both of these problems. It allows them to produce truly custom-fit chips on a larger scale than traditional manufacturing techniques.

Formlabs, which also manufactures plug-and-play 3D printers like the Form 3, recognizes the potential to make custom headphones more readily available.

"Our technology collaboration with Sennheiser is changing the way customers interact with the brands they love by enabling a more customized, user-centric approach to product development," said Iain McLeod, Formlabs' head of audio.

"Formlabs' deep industry knowledge and extensive expertise in developing scalable solutions enables us to deliver tangible innovations to our customers. In this case, we worked with Sennheiser's Ambeo team to provide a uniquely accessible custom-fit experience"

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However, the chip itself is still in the prototype stage, so there is no word on when it will be available. Sennheiser should be aware of this, as it will naturally be more expensive than using the mass-produced included ear tips, but probably considerably less expensive than the current custom-made options.

Plans for 3D printed earphone components are also likely to be involved in Sennheiser's sale of its consumer business.