Hearing Aid Case - Jabra Enhance Select 500

These hearing aids come with a really nice charging case that contains a rechargeable lithium battery to charge the aids.  But that makes the included case a bit bulky.  While it can fit in your pocket, it sticks out and it's not something you want to carry with you if you don't need the charging capability.

But, there are many times when you want to remove your hearing aids, or just have them in your pocket in case you need them.  Unfortunately, the oddball shape of the aids and wires make it impossible to stuff these in your pocket without risk of damage.  So I made this much smaller, thinner case that's small enough to carry with you everywhere, and store your hearing aids in them when you need to.  

They are designed to fit the Jabra Enhance Select 500 aids, but there is a little slack so the Select 300 will probably fit, although I don't have those so I can't verify.  When placing the aids in the case, the earbuds protrude upward as can be seen in my photos.  But the case is designed so that when it closes, it gently pushes the buds towards the front, and nestles them into cavities in the top of the case.  The slight torsional rotation of the wires when doing so poses no risk of actually bending them.

Additional parts you'll need:

1.5mm stainless steel rod

1mm self-adhesive foam 

Four 6x3mm magnets

I printed the case using Bambu Metal PLA in Iron Gray and Bambu PLA Silk in Copper color. 

The stainless steel rod is used for the hinge pin.  It should be press-fit, but you may need to taper the end before insertion, and you may need to ream the hinge-pin hole a bit with a properly sized drill bit.  I cut pieces of the 1mm adhesive foam for the bottom of the hearing aid cavities, and also for a strip along the inside of the top.  These hold the aids in place without risk of scratching them.  The case is sized to accommodate the extra 1mm top and bottom.  The magnets should be press fit, but may need a drop of CA if not.

Overall size of the case is 50mm side-to-side, 57mm front-to-back, and 19.5mm thick.