Normal is a company in New York City that is using 3D printing to develop a gadget that many of us rely on every day – earphones. Earphones are a cherished component of smartphones, mp3 players, tablets, and computers. In the earphones industry, there are a wide variety of options available, ranging in size, shape, material, and sound quality. But even with this abundance of choices, it can be difficult to find a comfortable pair that fits perfectly in your ear and remains tight in place through basic activities.
At Normal, CEO Nikki Kaufman’s frustration with ill-fitting headphones fueled her desire to find a design solution. She discovered that the only application currently used for customization was silicone molding, a process which can cost up to several thousand dollars per unit. But her knowledge of additive manufacturing lead her to come up with the idea to use 3D printing as a primary method of production.
By using Normal’s mobile app, or visiting Normal’s retail headquarters in Chelsea New York, consumers simply get photos taken of their ears. Normal processes the photos, and then 3D prints the lobe attachment with ABS thermoplastic, using a Fortus 250. The earphones can be printed in a variety of colors and the entire printing, manufacturing, and assembly process is done on site, in full view for customers to observe. And in case you’re wondering, the earphones have premium sound quality, on par with many of the upper end brands out today.
As you can see, 3D printing has become the foundation for Normal’s production process and business model. It has allowed them to link customization with mass production, in a way that is both practical and profitable.
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