When Loop first burst onto the scene with their innovative earplugs, they relied on 3D printing to bring their vision to life.
It quickly became clear that Loop needed a manufacturing process that could keep up with the growing demand without breaking the bank. While injection molding offered the speed and efficiency required for mass production, it came with its own challenges.
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The original design, optimized for 3D printing, needed significant adjustments to fit the new process. Given the earplugs' small size and intricate details, the team had to rethink everything. The solution? A clever redesign that split the earplugs into two separate components, seamlessly fused together using ultrasonic welding, delivering the same sleek look and feel as the original.