INTERTON RIE Custom Insert. Global Technical Operations gto.gnresound.com Lautrupbjerg 9 DK-2750 Ballerup Denmark

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1 INTERTON RIE Custom Insert Global Technical Operations gto.gnresound.com Lautrupbjerg 9 DK-2750 Ballerup Denmark Service@gnresound.com

2 Table of contents MPG Quick tips...3 Materials / Tools needed for MPG...4 MPG Custom Insert Tip Process HPG Materials / Tools needed for HPG...10 HPG Custom Insert Tip Process RIE Removal Removal of MPG / HPG from earmould...17 Page 2 of 17

3 Quick Tips Make sure the shell is deep enough so the entire Custom Insert Tip can fit into it. Make sure that the planned canal tip of the earmould is completely flat by sizing it down, to ensure strong gluing. If needed, the earmould canal tip can be recessed to accomodate the Custom Insert Tip. Make sure that the Custom Insert Tip do not have any cracked corners. - If the corners are cracked, the retention on rec will not be strong enough to prevent it from being pulled out of the ear bmould when it sits in the ear. - If the Custom Insert Tip is undamaged when it is mounted, then there is no danger of detachment. Do not insert Rec into the Custom Insert Tip before it is mounted in the earmould. - It will create cracked corners. Do not mount the outer waxguard until the Custom Insert Tip is mounted in the earmould. You might squeeze the Custom Insert Tip and damage it. Page 3 of 17

4mm drill for removal cord HF3 filterr 539-047-000-00 (blue)

Adhesive/glue Red colour for right - blue for left Custom

Technical Manual INT RIE Any drill bit can be chosen as long

4 Materials / Tools for MPG 1.6mm round burr for color dot 5 mm drill Ear Impression 0.4mm drill for removal cord HF3 filterr (blue) (red) Pick Sportlock p/n Adhesive/glue Red colour for right - blue for left Custom Insert p/n Removal cord Receiver tube P/n s: See Technical Manual INT RIE Any drill bit can be chosen as long as the correct diameter is used. All parts/materials with no p/n indicated should be sourced locally Page 4 of 17

MPG Custom Insert Tip Process Ear Impression material Sculpt the top of canal as flat as possible.

Fill custom insert tip with impression material. Insert a pick in the middle of the impression and let it cure.

Place insert tip between the first (1) and second bend (2) If width of the canal from 2. bend to 3.

5mm, then they are not a candidate of the earmould Custom Insert Tip Option Insert notches area Color Dot HF3 1.

Create a clear UV shell by using standard UV shell making - using negative mold Plan tip hole to be off centered

5 MPG Custom Insert Tip Process Ear Impression material Sculpt the top of canal as flat as possible. Do not round off edges Width Pick 2 1 Top view of the canal tip Length Custom Insert Tip 1. Fill custom insert tip with impression material. Insert a pick in the middle of the impression and let it cure. Slowly pull out the pick 2. Cut/sculpt the impression. Place insert tip between the first (1) and second bend (2) If width of the canal from 2. bend to 3. bend does not meet the required width and length of 6.5mm, then they are not a candidate of the earmould Custom Insert Tip Option Insert notches area Color Dot HF3 1.bend area 3. Create a clear UV shell by using standard UV shell making - using negative mold Plan tip hole to be off centered to make room for possible vent. If no space, center the tip hole. The tip is directional since it is not a perfect square. It is important that the long axis of the oval is towards the top which is where the color dot should be Left Insert Tip Vent Right 4. Drill a 5 mm hole for the insert. To start, use a small round burr to create pilot hole. Clean debris from shell after drilling Page 5 of 17

6 MPG Custom Insert Tip Process 5. Glue around Custom Tip and insert into the hole on the shell. Use any low aaviscous adhesive/glue 6. Insert the molded impression 7. Carefully fill shell with clear fill into the Custom Tip. No UV mat. up to the top of need to fully insert impression the Custom Tip. Remove fill material. Ideally, 3/4 in the bubbles prior to curing it on Insert would suffice the UV Light Chamber 8. Remove the molded 9. Using 1.6mm round burr, 10. Place a small dab of the acrylic color on the cavity. Fill the top of impression fill from the create a small cavity on the color dot with clear UV material until it is flushed even with Custom Insert Tip the side to add color dot the side of the mould. Then cure it with UV light Page 6 of 17

MPG Custom Insert Tip Process Excess material Size down the clear earmould as close to the length of the insert as

Level the excess shell material as shown above For small canals, there might not be room for a vent.

It s ok to drill through the flange of the Custom Insert Tip as long as the middle of the Custom Insert Tip is not

7 MPG Custom Insert Tip Process Excess material Size down the clear earmould as close to the length of the insert as possible. This will allow the use of sportlock. if the shell is not sized down, a sportlock cannot be added 11. Level the excess shell material as shown above For small canals, there might not be room for a vent. Make the Custom Insert Tip Option with no vent. Custom Insert Tip flange If possible, try to fit a vent. It s ok to drill through the flange of the Custom Insert Tip as long as the middle of the Custom Insert Tip is not compromised as this is where the outer HF3 will be placed 12. Drill the vent hole. Start aafrom the top of the canal Left Vent Right Page 7 of 17

MPG Custom Insert Tip Process Green circles are possible areas for

Drill the removal cord hole using a 0.4mm drill bit about 3mm deep 14.

earmould and buff to finish end following the process for Adding

which is centrally located on the Custom Insert Tip.

8 MPG Custom Insert Tip Process Green circles are possible areas for removal cord location for either left or right side 13. Drill the removal cord hole using a 0.4mm drill bit about 3mm deep 14. Dip one end of the cord using Loctite 416 glue and insert in the hole on the mould. Create 15. Round the edges of the canal including the Custom Insert Tip flanges that protrudes the sides of the canal. Round also all around the bottom of the small bead at the other the earmould and buff to finish end following the process for Adding Removal Cord for Custom Products Do not compromise the HF3 seating hole which is centrally located on the Custom Insert Tip. Any modification on this area will prevent the HF3 filter to sit properly HF3 Color dot Sportlock placement Vent 16. Insert the Receiver Tube into the earmould with Custom Insert Tip Vent Page 8 of 17

MPG Custom Insert Tip Process Color dot 18.

9 MPG Custom Insert Tip Process Color dot 18. Add HF3 on the outer area of the Custom Insert Tip Space for HF3 Space for Receiver Tube 17. Add sportlock by sliding it through the groove on the side of the receiver tube Receiver Tube 2. Sportlock 3. Vent 4. HF3 5. Custom Insert Tip 6. Color dot 7. Removal cord Page 9 of 17

Materials / Tools Needed for HPG 1.6mm round burr for color dot Ear Impression HPG custom insert tool p/n 15989100 0.

10 Materials / Tools Needed for HPG 1.6mm round burr for color dot Ear Impression HPG custom insert tool p/n mm drill for removal cord HF3 filterr (blue) (red) 2.4 mm round burr for rec hole Sportlock p/n Adhesive/glue HPG custom insert tip p/n Red colour for right - blue for left HPG Gasket p/n Removal cord Receiver tube P/n s: See Technical Manual INT RIE Any drill bit can be chosen as long as the correct diameter is used. All parts/materials with no p/n indicated should be sourced locally Page 10 of 17

HPG Custom Insert Tip Process Rib inside Insert Sculpt the top of canal as flat as possible.

This will prevent any UV material from leaking in the insert tip.

Pull the tip with two fingers while other fingers of the other hand pulls the insert tip.

Place insert tip between the first (1) and second bend (2) Top view of the canal tip Length If width of canal from

5mm, then they are not a candidate of the earmould HPG Custom Insert Tip Option Left Color Dot HF3 Right 3.

11 HPG Custom Insert Tip Process Rib inside Insert Sculpt the top of canal as flat as possible. Do not round off edges Width Area of insert Tool for the rib inside the Custom Insert Align tool & Insert 1. Insert Insert tool into the insert tip. Align the no notches area of insert tool to the rib located on inside one corner of insert tip. This will prevent any UV material from leaking in the insert tip. Press insert tool until the little nubbin part of the tip of insert tool is exposed through insert tip. Pull the tip with two fingers while other fingers of the other hand pulls the insert tip. Do this until insert tip is fully inserted into the insert tool Cut/sculpt the impression. Place insert tip between the first (1) and second bend (2) Top view of the canal tip Length If width of canal from the 2. bend to the 3. bend does not meet the required width and length of 6.5mm, then they are not a candidate of the earmould HPG Custom Insert Tip Option Left Color Dot HF3 Right 3. Create a clear UV shell by using standard UV shell making - using negative mold Insert Tip Vent Plan the Insert Tip hole to be off centered to make room for possible vent. If no space, center the Insert Tip hole 4. Drill a hole for the tip like a rec hole. Use 2.4mm burr which is 0.1 mm smaller than the diam of the Insert Tool tip. Clean debris from shell after drilling Page 11 of 17

HPG Custom Insert Tip Process Left Right 5. Drill a vent hole and add vent wire along inside of vent.

small canals, there might not be room for a vent. Make the Insert Tip Option with no vent. If possible, try to fit a vent 6.

rec hole Top rib of Insert Tool ~ ~ ~ ~ ~ ~ ~ ~ 7.

Cure for 2 min a(1200 Flashes with Wilde box) Add additional UV mat to the level of the top rib of Insert Tool.

Cure for 2 min (1200 Flashes with Wilde box) Invert the mold and cure the tip of the ear for 2 min (1200 Flashes awith awilde

Clean out ear mold by using air pressure through the HPG Custom Insert Tip from the receiver side.

12 HPG Custom Insert Tip Process Left Right 5. Drill a vent hole and add vent wire along inside of vent. If there isn t enough space, make the mould without vent and just add it later on when it is cured and sized down Vent For small canals, there might not be room for a vent. Make the Insert Tip Option with no vent. If possible, try to fit a vent 6. Insert the Insert tool with HPG Custom Insert Tip into the clear shell until the tip of the Insert Tool is through the drilled rec hole Top rib of Insert Tool ~ ~ ~ ~ ~ ~ ~ ~ 7. Do a three step process in filling UV material on the shell: Fill mold with clear UV mat. to just above HF3 guard area. Cure for 2 min a(1200 Flashes with Wilde box) Add additional UV mat to the level of the top rib of Insert Tool. Do not fill up ato the top of the Insert Tip. Cure for 2 min (1200 Flashes with Wilde box) Invert the mold and cure the tip of the ear for 2 min (1200 Flashes awith awilde box) 8. Slowly pull out the Insert Tool. Clean out ear mold by using air pressure through the HPG Custom Insert Tip from the receiver side. The Insert Tool can be re-used at least about 3 times if the Insert Tool is properly used. If there is any damage on the Insert Tool after removal from the earmould, replace it It may be necessary to carefully use a pick to try to remove bubbles trapped in the crevices. As the Insert Tool with Insert Tip and vent wire are lodged in the clear shell, it is possible that bubbles will form when pouring UV clear material to fill in the gaps. Page 12 of 17

HPG Custom Insert Tip Process 9. Using a 1.

Place a small dab of the acrylic color on the cavity.

Cure it with UV light Excess material 11. Level the excess shell material as shown above.

Add HF3 - Continue to size down top of the canal until it is almost flush with the HF3 installed.

13 HPG Custom Insert Tip Process 9. Using a 1.6mm round burr, create a small cavity on the side the mould to add color dot 10. Place a small dab of the acrylic color on the cavity. Fill the top of the color dot with clear UV mat until it is flushed even with the side of the mould. Cure it with UV light Excess material 11. Level the excess shell material as shown above. - Size down the top of canal until the receiver hole opening can fit the HF3. Add HF3 - Continue to size down top of the canal until it is almost flush with the HF3 installed. - Clean debris and remove old HF3 filter and replace with a new one. - Size down the bottom of the clear earmould as close to the length of the HPG Custom Insert Tip as possible. - This will allow the use of sportlock. If the shell is not sized down, a sportlock cannot be added. Page 13 of 17

Highlighted in green circles are possible areas for removal cord

Dip one end of the removal cord using Loctite 416 glue and insert in

14 HPG Custom Insert Tip Process 12. Round the sharp edges of the tip of the earmould canal and buff to finish 13. Round all around the bottom of the earmould and buff to finish Highlighted in green circles are possible areas for removal cord location for either left or right side 15. Dip one end of the removal cord using Loctite 416 glue and insert in the hole on the mould. Create the small bead at the other end following the process for Adding Removal Cord for Custom Products 14. Drill the removal cord hole using a 0.4mm drill bit about 3mm deep Page 14 of 17

15 HPG Custom Insert Tip Process Color dot Gasket HP CUSTOM TIP p/n HPG Custom Insert Tip 16. Using tweezers, place the gasket all the way to the bottom of the HPG Custom Insert Tip inside the earmould Sportlock placement HF3 Color dot Sportlock placement Vent Vent 17. Insert the HP Receiver Tube into the earmould with HPG Custom Insert Tip Page 15 of 17

HPG Custom Insert Tip Process Color dot 18.

6 5 2 1. Receiver Tube 2. Sportlock 3. Vent 4.

16 HPG Custom Insert Tip Process Color dot 18. Add Sportlock by sliding it through the groove on the side of the rec tube 19. Add HF3 on the outer area of the Insert Tip Receiver Tube 2. Sportlock 3. Vent 4. HF3 5. Custom Insert Tip 6. Color dot 7. Removal cord 4 3 Page 16 of 17

Removal of MPG / HPG from Earmould Wax Remover Tool to be

p/n 1186801) Modify the wire loop using a tweezer through it.

the sportlock (if present) from the receiver in the earmould

Place the modified removal tool wire on the sportlock

rec from earmould while holding the earmould firmly with one

has been used more than once or the rec is placed in too

17 Removal of MPG / HPG from Earmould Wax Remover Tool to be used as removal of RIE in ear mould (use e.g. p/n ) Modify the wire loop using a tweezer through it. This will open the wire loop Sportlock Feature area Remove the sportlock (if present) from the receiver in the earmould Get a firm grip with one hand on the earmould with receiver Place the modified removal tool wire on the sportlock feature area on the receiver Gently pull tool away pulling rec from earmould while holding the earmould firmly with one hand The wire loop is strong enough to pull out the rec from the earmould. It is possible for the wire loop to break especially if it has been used more than once or the rec is placed in too tight in earmould. If tool breaks, get a new one and continue the same process until receiver is removed from earmould Page 17 of 17

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