# US 10,122,989 B2 · Custom earbud scanning and fabrication > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,122,989 B2 - Document ID: US10122989B2 - Status: Granted - Kind: B2 - Application number: 15/289,061 - Filed: 2016-10-07 - Published: 2017-04-13 - Granted: 2018-11-06 - Earliest claimed: 2015-10-09 - Assignees: Lantos Technologies, Inc. - Applicants: Lantos Technologies Inc. - Inventors: Robert J. Fei; Michael L. Rishton; Jonathan Aguilar; Lydia Gregoret; Keith Guggenberger; Brett Zubiate; Brian J. Fligor; Xiaowei Chen; David J. Wilfert - Web page: https://patentgrep.com/patent/US10122989B2 ## CPC - H04N 13/25: using two or more image sensors with different characteristics other than in their location or field of view, e.g. having different resolutions or colour pickup characteristics; using image signals from one sensor to control the characteristics of another sensor - A61B 1/00172: {with means for scanning} - A61B 1/227: for ears, i.e. otoscopes - A61B 5/0064: {Body surface scanning} - A61B 5/0073: {by tomography, i.e. reconstruction of 3D images from 2D projections (A61B5/0066 takes precedence)} - A61B 5/1076: {for measuring dimensions inside body cavities, e.g. using catheters (A61B3/1005 takes precedence)} - A61B 5/1077: {Measuring of profiles} - A61B 5/1079: {using optical or photographic means} - A61B 5/6817: {Ear canal} - A61B 5/7203: {for noise prevention, reduction or removal} - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 50/00: Data acquisition or data processing for additive manufacturing - H04N 13/254: in combination with electromagnetic radiation sources for illuminating objects - H04R 1/1016: {Earpieces of the intra-aural type} - H04R 1/1058: {Manufacture or assembly} - H04R 25/658: {Manufacture of housing parts} - A61B 5/0071: {by measuring fluorescence emission} - A61B 5/1127: {using markers} - H04N 23/51: Housings - H04N 23/555: {for picking-up images in sites, inaccessible due to their dimensions or hazardous conditions, e.g. endoscopes or borescopes} - H04R 25/652: {Ear tips; Ear moulds (hybrid ear moulds or post-processing thereof for their customisation H04R25/659)} - H04R 2460/15: Determination of the acoustic seal of ear moulds or ear tips of hearing devices - H04R 2460/17: Hearing device specific tools used for storing or handling hearing devices or parts thereof, e.g. placement in the ear, replacement of cerumen barriers, repair, cleaning hearing devices - H04N: PICTORIAL COMMUNICATION, e.g. TELEVISION - A61B: DIAGNOSIS; SURGERY; IDENTIFICATION (usefulness limited to only animals A61D) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - H04R: LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS (producing sounds with frequency not determined by supply frequency G10K) ## Abstract A system includes a first scanner having an inflatable membrane configured to be inflated with a medium to conform an exterior surface of the inflatable membrane to an interior shape of a cavity. The medium attenuates, at first rate per unit length, light having a first optical wavelength, and attenuates, at a second rate per unit length, light having a second optical wavelength. An emitter is configured to generate light to illuminate the interior surface and a detector is configured to receive light from the interior surface. The scanner further includes a processor configured to generate a first electronic representation of the interior shape based on the light. A design computer is configured to modify the first electronic representation into a three-dimensional shape corresponding to at least a portion of the interior shape and a fabricator configured to fabricate, based at least on the modified first electronic representation, an earbud. ## Claims ### Claim 1 A system comprising: a first scanner comprising: an inflatable membrane configured to be inflated with a medium to conform an exterior surface of the inflatable membrane to an interior shape of a cavity, the medium attenuating, at first rate per unit length, light having a first optical wavelength, and attenuating, at a second rate per unit length, light having a second optical wavelength; an emitter configured to generate light to illuminate an interior surface of the inflatable membrane; a detector configured to receive light from the interior surface of the inflatable membrane, the received light comprising light at the first optical wavelength and the second optical wavelength; and a processor configured to generate a first electronic representation of the interior shape based on the received light; a design computer configured to modify the first electronic representation into a three-dimensional shape corresponding to at least a portion of the interior shape; and a fabricator configured to fabricate, based at least on the modified first electronic representation, an earbud, wherein the first scanner comprises a scanning tip, wherein the scanning tip comprises the emitter and the detector, and wherein the scanning tip is configured to actuate between an extended position and a retracted position. ### Claim 2 (depends on 1) The system of claim 1, further comprising: a second scanner comprising a structured light source and a camera, the second scanner configured to generate a second electronic representation of a second shape, the second shape being of at least one of: a second interior shape of a portion of the cavity; and a second portion of a second surface proximate to the cavity. ### Claim 3 (depends on 2) The system of claim 2, wherein the design computer is further configured to merge the first electronic representation and the second electronic representation into a combined electronic representation of the interior shape and the second shape. ### Claim 4 (depends on 2) The system of claim 2, wherein the second scanner is coupled to the first scanner. ### Claim 5 (depends on 1) The system of claim 1, wherein the fabricator comprises at least one of: a mold for the earbud, the mold based at least on the interior shape; a three-dimensional printer or digital light processing system; and a second apparatus configured to add one or more additional components to the earbud, the one or more additional components comprising at least one component for delivering sound to an area proximal to the earbud. ### Claim 6 (depends on 5) The system of claim 5, wherein the three-dimensional printer is configured to fabricate an object comprising a shell with a predetermined thickness, and wherein the shell corresponds to the interior shape. ### Claim 7 A method comprising: performing a first scan, with at least a first scanner, of an interior shape of a cavity, the first scan of the interior shape comprising: inflating an inflatable membrane with a medium, the inflating of the inflatable membrane conforms an exterior surface of the inflatable membrane to the interior shape of the cavity; generating light from an emitter to at least illuminate an interior surface of the inflatable membrane; detecting, at a detector, light from the interior surface of the inflatable membrane, the light comprising a first optical wavelength and a second optical wavelength; and generating, at a processor, a first electronic representation of the interior shape, the generating being based at least on the detected light; performing a second scan of a second shape proximate to the cavity, the second scan of the second shape generates a second electronic representation of the second shape; modifying, at a design computer, the first electronic representation into a three-dimensional shape corresponding to at least a portion of the interior shape; generating, at the design computer, a combined electronic representation comprising the first electronic representation and the second electronic representation; fabricating, at a fabricator, an earbud, the fabricating based at least on the combined electronic representation; and actuating, between an extended position and a retracted position, a scanning tip, the scanning tip comprising the emitter and the detector and the scanning tip being actuated during the generating and detecting of the light. ### Claim 8 (depends on 7) The method of claim 7, wherein the second scan is performed by a second scanner, wherein the second scanner comprises at least one of the first scanner, a structured light source and a camera, and a laser rangefinder. ### Claim 9 (depends on 7) The method of claim 7, further comprising: illuminating a surface with a structured light source, the structured light source emitting light having spatial variations of intensity or wavelength; imaging the illuminated interior surface with a camera, wherein the imaging generates one or more images resulting from the light having spatial variations; and generating, based at least on the one or more images, the second electronic representation of the surface. ### Claim 10 (depends on 7) The method of claim 7, wherein the first electronic representation is generated based at least on measurements of absorption of the light at the first optical wavelength and measurements of absorption of the light at the second optical wavelength. ### Claim 11 (depends on 7) The method of claim 7, further comprising: identifying, based at least on the second electronic representation, one or more native references within the interior shape and the second shape; and combining, based at least on the one or more native references, a plurality of electronic representations. ### Claim 12 (depends on 7) The method of claim 7, wherein the fabricating comprises at least one of: forming, based at least on the interior shape, a mold for the earbud; fabricating the earbud with a three-dimensional printer or a digital light processing system; and adding, with a second apparatus, one or more additional components to the earbud, one or more the additional components comprising at least one component for delivering sound to an area proximal to the earbud. ### Claim 13 A method comprising: performing a first scan, with at least a first scanner, of an interior shape of a cavity, the first scan of the interior shape comprising detecting, at a detector, light comprising a first optical wavelength and a second optical wavelength, the detected light generated by at least one of: detecting structured light generated from a pattern imprinted on an interior surface of an inflatable membrane; and emitting, by an emitter, structured light to form a pattern on the interior surface of the inflatable membrane conforming to an interior shape of an ear and the detected light generated by reflection of the structured light from the interior surface; and generating, at a processor, a first electronic representation of the interior shape, the generating being based at least on the detected structured light; performing a second scan of a second shape proximate to the cavity, the second scan of the second shape generates a second electronic representation of the second shape; modifying, at a design computer, the first electronic representation into a three-dimensional shape corresponding to at least a portion of the interior surface; generating, at the design computer, a combined electronic representation comprising the first electronic representation and the second electronic representation; fabricating, at a fabricator, an earbud, the fabricating based at least on the combined electronic representation; and actuating, between an extended position and a retracted position, a scanning tip, the scanning tip comprising the emitter and the detector and the scanning tip being actuated during the generating and the detecting of the light. ### Claim 14 (depends on 13) The method of claim 13, wherein the second scan is performed by a second scanner, wherein the second scanner comprises at least one of the first scanner, a structured light source and a camera, and a laser rangefinder. ### Claim 15 (depends on 13) The method of claim 13, further comprising: illuminating a surface with a structured light source, the structured light source emitting light having spatial variations of intensity or wavelength; imaging the illuminated interior surface with a camera, the imaging generates one or more images resulting from the light having spatial variations; and generating, based at least on the one or more images, the second electronic representation of the surface. ### Claim 16 (depends on 13) The method of claim 13, wherein the first electronic representation is generated based at least on measurements of absorption of the light at the first optical wavelength and measurements of absorption of the light at the second optical wavelength. ### Claim 17 (depends on 13) The method of claim 13, further comprising: identifying, based at least on the second electronic representation, one or more native references within the interior shape and the second shape; and combining, based at least on the one or more native references, a plurality of electronic representations. ### Claim 18 (depends on 13) The method of claim 13, wherein the fabricating comprises at least one of: forming, based at least on the interior shape, a mold for the earbud; fabricating the earbud with a three-dimensional printer or a digital light processing system; and adding, with a second apparatus, one or more additional components to the earbud, one or more the additional components comprising at least one component for delivering sound to an area proximal to the earbud.