Quote:
Originally Posted by Zoide
So, to bring this post back to the thread topic, I'd say we shouldn't take the precision of IEM makers as being all that impressive (at least for Sensas).
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I think it's easy to say that due to your personal experience... but I think it has to be put in perspective in respect to how the process itself is actually achieved.
For Sensaphonics, it isn't simply a process of taking your ear impressions, making a mold out of it, and then pouring materials into the mold until it cures. They take a look at your impression, then make adjustments to the mold as to what information is needed, what isn't, what, by their experience makes a more comfortable fit if made a certain way. Basically they're still taking a blind guess on an approximation of what you will be happy with, your impression isn't 100% the same shape as what your IEM eventually will look like.
For example, your impression is not going to fortell the rigidity of your cartillage structure in which to hold the IEM securely in place at all time, how much should they extend the top flap to fit snugly in place? How much do they adjust the bottom extensions? All those things come by experience of the technician putting it together.
This is farther complicated by the soft silicone material that they use, which fills out your ear very snugly, ensuring the best seal possible and maintain comfort at the same time. The additional closeness of the IEM makes the slight amount of deviation even more apparent.
Furthermore, Sensaphonics is a one-piece construction, which means everything is formed and molded in a single process. This makes some of the internal driver placement and tube placement and such a bit harder, I would imagine. Also the driver housing, including the entire silicone mold, is smaller in size than the UE products. Which means they're trying to squeeze those two drivers into an even smaller space, to make them look as inconspicuous as possible. I suspect a combination of the two, probably later more so, is the reason why your tube was close to being pinched.
Of course, your earshape plays a lot into that as well, there's no guarantee that UE product wouldn't be equally pinched due to your ear shape. For example, I've never had any problem, whatsoever with my Sensaphonics nor UE's in terms of fit & comfort. My Sensa's sound tubes are literally straight from point A to point B.
In comparison to UE.. Ultimate Ears fit comfortably, but not "snugly"... They don't make their IEM as "closely fit" as the Sensas.. because they use a hard acrylic material, it simply wouldn't be comfortable to make it more snug. The manufacturing process is also a two-piece construction. They make a half-shell, drill out and place the drivers, and then form the other half-shell... glue them together and sand down 'til the merging plane is almost invisible (but if you look closely, you'll still find them).
This two-piece construction process with a hard material is much, much easier to achieve than a single-piece process with a flexible, soft material.