Project

Ear Piece Medical Device Manufacturing

Manufacturing and assembling ear-worn bioelectronic devices at Evren Technologies, from injection-molded silicone housings to electrode fabrication and final assembly.

Engineering Intern, Evren Technologies

Evren's Phoenix controller next to an assembled ear-worn bioelectronic earpiece fitted to a silicone ear model, showing the CH1 channel active and prompting to insert the earpiece. — The Phoenix controller alongside an assembled earpiece, fitted to a silicone ear model for bench testing.

Overview

As an Engineering Intern at Evren Technologies, I manufacture, assemble, and test the company's ear-worn bioelectronic devices end-to-end, work that gets paired with Evren's Phoenix controller for bench testing and validation.

Design Process

Injection-mold silicone earpiece housings using 3D-printed molds
Cut and prepare electrodes, then wire and assemble complete earpieces
Perform quality checks and troubleshooting to support production readiness
Apply DFM principles to electrode fabrication and assembly workflows to improve repeatability and reduce production time
Design housing components in Onshape and validate fit with 3D-printed prototypes for rapid iteration

What I Learned

Working across the full build, from a 3D-printed mold to a finished, wired earpiece, showed me how much a device's manufacturability depends on decisions made well before assembly. Small tolerances in the mold or electrode placement carry all the way through to how repeatable and production-ready the final device is.

Tools and Skills

OnshapeDesign for Manufacturability (DFM)Injection Molding3D PrintingElectrode FabricationQuality Control