Navy Awards Five-Year Contract for 3D Scanned Hearing Protection

The Naval Air Systems Command's Aircrew Systems Program Office (PMA-202) has awarded Aware Defense a sole-source Program of Record contract to supply custom hearing protection and Communications Earplugs (CEP) to Naval Aviation aircrew and flight-line maintainers. The five-year agreement makes Aware Defense the Navy's exclusive end-to-end provider for 3D digital ear scanning, manufacturing, and delivery.

How It Works

Aware Defense's program is built around its eFit 3D ear scanning system. The company describes eFit as the only non-contact optical scanner that uses radial illumination to capture ear and ear canal geometry past the second bend. The scanner achieves dimensional accuracy under 90 microns, which is precise enough to produce a hearing protector that actually seals properly.

Once the scan is complete, the device is manufactured using additive manufacturing. The entire pipeline is digital: scan, design, print, ship. No physical ear impressions or multi-week lab turnaround.

From Pilot to Fleet-Wide Deployment

This contract follows an earlier phase of initial program funding. Between September 2025 and July 2026, Aware Defense ran on-site scanning events across the country and delivered 6,373 custom-fit devices alongside NAVAIR Aeromedical Safety Officers and Navy audiologists.

Under PMA-202, the company now plans to scale production to 42,000 custom-fit units starting August 1, 2026, across Naval Air Stations both in the continental United States and overseas.

Why Hearing Loss Matters Here

Hearing loss is one of the most common service-connected disabilities among military personnel. Standard one-size-fits-all earplugs do not seal consistently across different ear shapes, which is why a custom-fit approach makes a real difference. If the device fits correctly, it gets worn. If it gets worn, hearing is protected.

This contract is one of the clearest examples of additive manufacturing moving from a research pilot into an institutional military supply program at scale.