Case Study: WS Audiology achieves faster delivery and better-performing production tooling with 3D Systems' Figure 4

Hearing Aid Company Solves Manufacturing Challenges with Rigid and Rubber 3D Printing Production Resins on Figure 4 Solution

WS Audiology, a leading hearing-aid manufacturer, faced recurring production challenges moving very small injection-molded components (some as small as 8 × 3 mm). Suction cups struggled to orient parts reliably and metal grippers left marks and had long lead times, creating quality, performance and delivery bottlenecks on the assembly line.

To address this, WS Audiology adopted 3D Systems’ Figure 4 high-speed 3D printing at its Lynge, Denmark site to produce production-grade rigid and rubber grippers, jigs, fixtures and prototypes using materials like PRO-BLK 10 and RUBBER‑65A 65A. The approach eliminated tooling, enabled rapid design iteration and delivered parts in 1–2 days, improving part quality and handling (soft-grip replacement for metal), increasing throughput (roughly 200 grippers, 100 fixtures and 500+ prototypes annually) and shortening delivery times.

WS Audiology

Henry Frederiksen

Tool Designer