Hearing aid with a flexible shell

A method of assembling a hearing aid comprising:

• casting a tip for a hearing aid, the tip having a receptacle for a receiver;
• providing a receiver;
• inserting the receiver into the receptacle within the tip;
• providing a second section housing;
• attaching the second section housing to the tip;
• applying potting material the receiver within the second section housing;
• providing a battery and flex circuit assembly;
• inserting a battery and flex circuit assembly within the second section housing;
• providing a microphone and housing assembly;
• mechanically securing a microphone and housing assembly to the second section housing;
• providing an actuator having a conductive surface;
• and
• inserting the actuator within the hearing aid, the actuator being electrically connected to the hearing aid without solder, the actuator allowing for powering of the hearing aid.

A hearing aid comprising:

• a first section, the first section having a first housing containing a microphone and electronics;
• a second section attached to the first section, the second section having a second housing containing a battery a flex circuit mounted around the battery;
• and
• a third section attached to the second section, the third section having a compliant tip and a receiver contained within a receptacle in the tip, the flex circuit electrically connecting the microphone, electronics, receiver and battery.