From audio production to biographical ear art using Asiga
By Benjamin Schadow B.A.
CEO HÖRSTIL GmbH & Co. KG in Erfurt
Established Reliability in Daily Production
In our daily laboratory workflow, we routinely manufacture custom earmolds using two Asiga MAX 3D printers. These systems have been fully integrated into our audiological production for years and are relied upon for their consistency, precision, and process stability. Defined print parameters, validated materials, and a structured digital workflow allow us to produce high-quality results on a daily basis. This level of technical reliability is essential in audiology, where fit accuracy and repeatability directly influence functional outcomes. At the same time, it creates something equally valuable: creative headroom. Once a workflow is stable and predictable, it becomes possible to explore applications beyond pure functionality.
MORELI – An Expressive Counterbalance
Out of this space emerged MORELI, a brand dedicated to biographical art objects worn within the individual ear anatomy. MORELI does not aim to replicate conventional jewelry. Instead, it exists at the intersection of audiology, digital design, and artistic expression. The concept of MORELI developed as an expressive counterbalance to the functional precision of everyday laboratory work. While earmolds are designed to serve a clearly defined medical
purpose, MORELI objects are created to give emotional states, personal history, and individual desires a physical form. Each piece is developed in a deep, dialog-driven process with the wearer and cannot be separated from their biography. The realisation of these objects is based on the deliberate combination of:
– Audiological expertise and anatomical knowledge
– Digital design tools
– High-precision 3D printing
– Traditional casting and goldsmith craftsmanship
A MORELI for Tattoo Artist Jule
The present case focuses on the development of a custom MORELI for Jule, a tattoo artist whose visual language is strongly defined by flowing lines, symbolism, and recurring motifs. From the outset, the goal was not simply to create an object that fits the ear, but one that integrates seamlessly into her existing body art.
The line work of the MORELI was designed to harmonise with the lines of her tattoos. Rather than appearing as an added accessory, the object was intended to feel like a natural extension of an already existing visual narrative. The central design element is a myrtle leaf pattern, a plant
traditionally associated with wild love. This motif connects to the floral forms present on Jule’s body and ear and aligns with the recurring subtheme “amore” found throughout her work.
Digital Design and Preparation
The entire form was developed digitally, drawing directly on audiological experience with ear anatomy. This knowledge allows for artistic freedom while maintaining wearability and anatomical harmony—a crucial factor when creating objects intended to be worn inside the ear. From the beginning, the design was optimized for casting. Wall thicknesses, transitions, and fine details were carefully considered to ensure that the printed model would perform reliably during burnout and metal casting, without compromising the artistic intent.
3D Printing with Asiga: Enabling Detail and Control
For the 3D printing stage, Supercast HD resin was used in combination with the Low Force Tray on the Asiga MAX. This setup was selected for its ability to reproduce extremely fine details while maintaining reliable separation forces during printing. A layer thickness of 0.025 mm was chosen to capture the smallest lines, textures, and transitions of the design. At this scale, print quality becomes a defining factor: subtle inaccuracies would immediately affect the visual coherence of the object.
Here, the experience gained from everyday earmold production proved invaluable. The predictability and flexibility of the Asiga setup, including its open material approach and precise process control, allowed the project to move forward without experimental uncertainty. The printer functioned not as a limiting factor, but as a trustworthy manufacturing tool within a creative
workflow.
From Printed Model to Finished Object
Following printing, the model was processed by Gehse Dental in Jena, where it was burned out and cast in silver using a vacuum casting process. The high resolution of the printed model ensured that all design details transferred accurately into the metal. Final finishing was carried out by our partner Schmuck und Objekt on the Krämerbrücke in Erfurt. The silver surface was first oxidised and then selectively gold-plated, creating depth, contrast, and visual tension. Throughout this process, the fine structures created during 3D printing remained clearly visible.
When Precision Creates Space for Expression
This MORELI object illustrates how high-precision 3D printing can support applications far beyond functional medical devices. Without the accuracy, repeatability, and flexibility of our Asiga setup, this unique piece would not have been possible in its final form.
At the same time, the case highlights a broader insight: artistic freedom does not emerge despite standardised workflows, but because of them. A controlled, well-understood manufacturing process provides the foundation on which creative, emotionally resonant objects can be realised.
About the Author
Born in 1987 in Ilmenau, Benjamin is a certified hearing care professional specialising in audiology and digital manufacturing. He qualified as a Hearing Care Professional in Lübeck in 2008 and completed his Master certification in Braunschweig in 2009. In 2010, he became a certified Audiotherapist (DSB) and later took on a management role in Erfurt. Between 2011 and 2015, he studied Business Administration and Psychology at Euro-FH Hamburg. In 2014, he founded the
HÖRSTIL studio in Erfurt, combining individualised hearing care with a design-oriented approach. Since establishing an in-house 3D printing laboratory in 2018, his work has focused on integrating high-precision additive manufacturing into daily audiological workflows.
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