Apple has been continuing to research AirPod design in the hunt for the best fit for most users, but now it may have a way to personalize the earbuds for every individual wearer. The question is how to get precise ear measurements for millions of users.
As AirPods and AirPods Pro have continued to improve their sound quality, Apple has also attempted to make them fit better in users' ears. Now a newly-granted patent called "Fabric-based earbuds" proposes the novel solution of customizing every pair for every buyer.
"An electronic device with a three-dimensional sensor may be used to capture three-dimensional images of one or both of the user's ears," says the patent. "The three-dimensional ear images may be provided to computing equipment that analyzes the images to determine the dimensions of the ear such as tragus and antitragus dimensions and concha dimensions."
Then having this data, 3D weaving equipment could "weave customized earbuds for the user based on the ear images."
Apple does go into some detail about this weaving, noting for instance that the "concha portion of the customized earbuds may be woven with slightly larger dimensions than the user's actual concha, as the concha area can withstand some compression without discomfort."
But the patent is really focused on the specifics of weaving fabric in three dimensions. That could also include Apple Watch bands, but the detail of the patent is on the challenges in "using woven fabric to form three-dimensional structures" such as AirPods.
So there's much in the patent about the precise way such weaving could be done, with enough specifics about weft strand, warp loops, and hooks, to satisfy the most dedicated weaver.
Detail from the patent discussing how 3D structures could be woven out of 2D fabric.-image credit: Apple.
It's not just about the fit, either, as Apple thinks fabric could be more appealing than plastic in so many ways. "Fabric-based items such as these may have an attractive appearance," says the patent, "and may benefit from desirable attributes associated with fabric such as sound permeability, light weight, and durability."
How this could work
There are more practical issues than how the weave is done, and little of that is covered in this patent. Specifically, there is the question of how to take those ear measurements for millions of customers.
The patent does make reference to measurements being made by that "electronic device with a three-dimensional sensor," but it doesn't specify anything further.
There has to be a possibility, though, that Apple could extend the process it created for the Apple Vision Pro where faces are scanned to find the right lenses. There was also the ability to check sizes for the original Apple Watch, although that was a bit more low-tech as it involved printing out pieces of paper to wrap around the user's wrist.
So given that iPhones now have Face ID and LiDAR, it could be that a way is made for users to do their own measurements.
However that element would work, though, it seems certain that the result would be a perfect fit for AirPods and AirPods Pro. That in turn would make these devices even better at passive noise cancellation.
This patent is credited to three inventors, including Kathleen A. Bergeron. Her previous work for Apple includes multiple patents on audio and fabric topics.
