The Lehigh Valley’s First Ear Mold Lab feat. Bob Holbrook and Ed Graham | ProtoCAM

About the Hearing Matters Podcast
 
The Hearing Matters Podcast discusses hearing technology (more commonly known as hearing aids), best practices, and a growing national epidemic - Hearing Loss. The show is hosted by father and son - Blaise Delfino, M.S. - HIS and Dr. Gregory Delfino, CCC-A. Blaise Delfino and Dr. Gregory Delfino treat patients with hearing loss at Audiology Services, located in Bethlehem, Nazareth, and East Stroudsburg, PA.
 

The Lehigh Valley’s First Ear Mold Lab

In this episode Blaise Delfino interviews Bob Holbroook and Ed Graham of ProtoCAM Additive Manufacturing in Allentown, Pa. Both Ed and Bob have extensive experience in the additive manufacturing field. (Additive manufacturing is more commonly known as 3-D printing.) Ed has been with ProtoCAM since 1996 after graduating from college as a polymer engineer. 

Bob owned his own injection molding company and began working at ProtoCAM After selling his business. ProtoCAM was Bob’s prototype, so his background combined with Ed’s engineering skills made for the perfect match. Together with CEO of ProtoCAM, Ron Belknap, the three have a total 75 years of experience. 

An Idea Meets Manufacturing 

Blaise met Ed and Bob at a conference where Blaise was giving a talk on Fader Plugs, the world’s first adjustable, mechanical ear plug, which he invented and patented. The ProtoCAM employees immediately wanted to get involved. They offered to help Blaise with the manufacturing of Fader Plugs. 

Prototyping Begins

Both were excited to get involved in the project, however, Bob was hesitant about making the fine parts inside the Fader Plugs and their biocompatibility. However, they were able to overcome the anticipated problems and move forward.

The filter was the start of ProtoCAM’s relationship with Fader Plugs. After several design iterations, Bob and Ed realized this was something that had never been developed before. Neither of them knew much about audiology in general, so it was a huge learning experience for everyone. After three iterations of the filter, it was recommended that the filter size be decreased. They did manage to decrease it by 67 percent; however, it did not function correctly. 

Turn-Around Time

This technology will enable a turn-around time of only a couple of days. This is important because those that need Fader Plugs are construction workers, musicians, people with hyperacusis, or anyone around continual noxious noise. It is important to get people into Fader Plugs as soon as possible so they can preserve their hearing. 

New Lab is Introduced

As a result of the partnership between Fader Plugs and ProtoCAM, the first ear mold lab ever in the Lehigh Valley has been introduced. This is groundbreaking. It is also something that ProtoCAM CEO Ron Belknap has always wanted to do: manufacture a product from start to finish. 

A Contribution to Society 

ProtoCAM is excited to be helping others maintain their hearing health. They are also very dedicated to their customers, in this case Fader Plugs, and want to manufacture only the best, highest quality goods. Also knowing that the entire product was invented and manufactured in the Lehigh Valley is thrilling.

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