PRODUCTION TIMELINE

Overall process

Manufacturing counts more than 100 steps all managed by a tailor made software: each employee has his own iPad and is guided at each task.

Impressions cleaning

Once the impressions are received they are cleaned with an anti-bacterial solution.

Scanner loading

The impressions are loaded into a special 3D scanner capable to scan both ears at the same time in 90 seconds.

Model design

Each in-ear is custom designed complying to the model of choice, the drivers and the electronic parts to fit inside.

Porcelain pouring

Porcelain mixed to a special photopolymer is poured into the moulds.

Post Curing

Parts extracted from the moulds are cured and dried for 24 hours in a proprietary oven.

Drilling holes

Holes are created in the number and dimension needed by the model chosen by the client.

Tray preparation

Alumina powder is stewed on top of the bases and the firing trays in order to avoid sticking.

First firing

The kiln is loaded with parts for the first firing process (called "bisque") that will go up to 1200° Celsius / 2200° Fahrenheit.

Glaze preparation

Lead-free water-based resins are prepared and dosed for the application on the parts according to the finishing chosen by the client.

Tray preparation

Parts are installed on special supports and transferred on top of the trays for the second firing.

Kiln unloading

The glossy and solid parts are removed from the kiln another 48 hours of firing and carefully inspected for quality.

Leather Case personalisation

The leather cases are personalised with the model logo and the name of the client along with the shells.

Inspection and test

All parts are inspected and tested in terms of sound-response and impedance.

Closing

The WAVAYA™ metallic logo is applied on the cIEM lid and the model is finally closed and ready.

Photographing

Photos are taken in case the specific combination of finishing, logo, shape and, eventually, Chrystal is not present in our archives.

Boxing

The case is set in the delivery box together with the guarantee card.

Packing

The custom in-ears along with some gadgets and accessories are prepared and packed in a box or a special shipping envelope.

Order entry

The order is registered into the system and the various elements are defined and sent to production.

Impressions cutting

Exceeding silicon is removed from the impressions in order to lower post-scanning design work.

3D scanning

Both ear impressions are scanned and converted into an editable format for 3d design.

Mould printing

Moulds are 3d printed with UV semi permeable resin in special cylinders with a size increase of around 18% from the original.

UV curing

Moulds are put into a UV chamber in order to obtain a cured shell with a thickness of about 1.2mm.

Filing and buffing

Parts are now filed and buffed in order to remove imperfections.

Preparing bases

Hexagonal clay bases are prepared in order to contain the parts during the first firing. Yes, we use a pasta machine!

Slot assignment

Each order is assigned to a specific base, properly marked and each part is collocated on the base accordingly.

Kiln unloading

After 48 hours of firing, the parts are removed from the kiln when the bisque has cooled down

Glaze application

The chosen glaze is applied on each part, by brush by specialised craftsmen and parts are moved to the drying oven.

Second firing

The trays are loaded into the kiln for the second firing that will confer a glossy finishing to glazes and solidity to porcelain.

Shells printing

The model logo is printed on each shell using a special uv printing machine.

Pre assembly

Drivers and electronic parts are pre-assembled using a provisional tubing that will be removed during the final assembly stage.

Assembly

Parts are transferred into the shells and fixed with our proprietary tubeless outlet system.

Final testing

The custom in-ears are subject to a final test in terms of aesthetics, sound response, impedance etc.

Casing

The custom in ears are set in their own case and in the packaging box with the guarantee card.

Sealing

The delivery box is then sealed with a thermo-retractile film.

Couriering

The bundle is prepared for shipping by FedEx™ and it will reach our client almost worldwide in a couple of days.

Optional steps

Metallic finishing

Metallic finishing requires a third firing performed at a temperature of around 600° Celsius, 1100° Fahrenheit.

Testing Facility

We offer a testing room to immediately try our custom in-ears in a live or studio environment directly in our factory in Nicosia, Cyprus.