Faceplate for a custom-fitted hearing device shell

A method of assembling an ear-wearable electronic device, comprising:

• digitally capturing an ear geometry of a user of the ear-wearable electronic device into a data file;
• using the data file to generate a geometry file of a shell having an outer surface that corresponds uniquely to the ear geometry of the user, the shell comprising a faceplate void that has a curved and beveled perimeter edge;
• 3D printing the shell using the geometry file;
• injection molding a faceplate having a beveled edge that mates with the perimeter edge, the faceplate comprising an unbroken covering surface that matches the outer surface of the shell surrounding the faceplate void, wherein the beveled edge of the faceplate and the beveled perimeter edge of the faceplate void have a stadium shape, and wherein the stadium shape is configured to allow mated edges and an unbroken covering surface when the faceplate void is manufactured at a tolerance limit;
• installing one or more devices into the shell through the faceplate void;
• and
• installing the faceplate within the faceplate void to seal the shell.

An ear-wearable electronic device comprising:

• a faceplate having a beveled edge;
• and
• a shell having an organically-shaped outer surface that corresponds uniquely to an ear geometry of a user of the ear-wearable device, the shell comprising:
• a faceplate void that has a curved and beveled perimeter edge, the faceplate void facilitating access to one or more devices installable into the shell;
• and
• one or more protrusions from an inner surface of the shell and blocking a part of the void, the one or more protrusions preventing the faceplate from passing through the void and into an interior volume of the shell, and wherein the faceplate is mated to the shell such that the beveled edge of the faceplate is in contact with the beveled perimeter edge of the faceplate void, and wherein an inner surface of the faceplate is separated from the one or more protrusions via a clearance gap;
• wherein the faceplate is installed in the faceplate void and the beveled edge mates with the perimeter edge, the faceplate comprising an unbroken covering surface that matches the outer surface of the shell surrounding the faceplate void.

A method of assembling an ear-wearable electronic device, comprising:

• digitally capturing an ear geometry of a user of the ear-wearable electronic device into a data file;
• using the data file to generate a geometry file of a shell having an outer surface that corresponds uniquely to the ear geometry of the user, the shell comprising a faceplate void that has a curved and beveled perimeter edge;
• 3D printing the shell using the geometry file;
• injection molding a faceplate having a beveled edge that mates with the perimeter edge, the faceplate comprising an unbroken covering surface that matches the outer surface of the shell surrounding the faceplate void;
• installing one or more devices into the shell through the faceplate void;
• and
• installing the faceplate within the faceplate void to seal the shell;
• wherein the shell further comprises one or more protrusions from an inner surface of the shell and blocking a part of the void, the one or more protrusions preventing the faceplate from passing through the void and into an interior volume of the shell when installing the faceplate within the faceplate void to seal the shell, and wherein the faceplate is mated to the shell such that the beveled edge of the faceplate is in contact with the beveled perimeter edge of the faceplate void, and wherein an inner surface of the faceplate is separated from the one or more protrusions via a clearance gap.