FEATHERWEIGHT® INSTANT SILICONES · FOR HEARING HEALTHCARE PROFESSIONALS
Deliver Premium-Grade Custom Earmolds and Protection in a Single Visit.
Eliminate lab wait times, shipping fees, and remakes by crafting premium, durable, 100% floatable silicone solutions right in your office in under 10 minutes.
The Clinical Application Suite
One versatile material adapts to every ear solution you deliver—custom hearing-aid earmolds, watertight swim plugs, and profitable hearing protection.
CUSTOM EARMOLDS FOR BTE HEARING AIDS
Same-Day Delivery. Zero Laboratory Wait Times.
Don’t force your patients to wait weeks for a permanent, accurately fitted earmold. With Insta-Mold Featherweight, you can deliver a premium, flawless acoustic fit during their very first visit—increasing patient satisfaction and accelerating your clinic’s workflow.
Core Clinical Solutions
- The Antidote to Acoustic Feedback: Traditional lab molds are a copy of a copy, and translational errors can create gaps and fit issues. Because Insta-Mold uses the patient’s ear as the negative, those issues are generally eliminated—the material cures live inside the ear canal, maintaining direct, uninterrupted contact throughout the entire canal and bowl of the ear, leaving no space for sound to escape from the hearing aid speaker. Pro Clinic Tip: Pair it with our Clear-Seal Silicone Coating to further tighten the fit and completely eliminate stubborn feedback.
- Rapid Adjustments for Growing Babies & Children: Pediatric patients outgrow their earmolds incredibly fast, making traditional lab re-fits a logistical and financial burden. At a fraction of the cost of a lab mold, new pediatric earmolds are a cinch to craft on the spot. If a child’s mold is slightly loose, simply apply a layer of Clear-Seal Silicone Coating to add precise size, reducing the number of total refits required as they grow.
- Instant Loaner & Testing Molds: Patients lose momentum when they have to wait weeks to try a new BTE hearing aid. Provide immediate delivery—patients can walk out with a perfectly programmed BTE hearing aid and a custom-fitted earmold on day one, keeping their trial or transition seamless.
- Portable Utility for Medical Mission Trips: Providing hearing healthcare in remote, underserved areas makes laboratory dependency impossible. The Featherweight system requires no lab equipment or electricity to cure, allowing you to create custom earmolds anywhere, anytime, for anyone on global mission trips.
Total Clinical Control
- Versatile Styles: Easily craft a Full Shell, Half Shell, or Canal Mold based on the patient’s cosmetic preference and amplification needs.
- Precision Finishing: Hand-modify the final product right at your desk—customize the canal length, vent it for pressure relief, or tube it seamlessly.
CUSTOM SWIM & WATER PLUGS
Ultimate Water Isolation. 100% Buoyant & Hydrophobic.
Protect your myringotomy, chronic infection, and surfer’s ear patients with a watertight barrier crafted right in your clinic. Give parents and athletes total peace of mind with premium custom plugs that repel water and never sink.
Core Clinical Solutions
- Advanced Hydrophobic Formulation: Crafted with specially treated organo-siloxane chemical groups, Featherweight silicone is truly hydrophobic (water-hating). It actively repels water molecules away from the ear surface, creating an impenetrable moisture barrier for post-surgical or vulnerable ears.
- 100% Floatable (Never Lose a Plug): Formulated with ultra-lightweight, high-strength reinforcing fillers, Featherweight molds have a density lower than water—they will not sink. If dropped in a crowded pool, a lake, or a bath, they stay right on the surface for instant retrieval.
- Clinically Proven & Published Protection: Safety and efficacy are backed by peer-reviewed research. Insta-Mold is the only instant earmold system with a published procedure in the Archives of Otolaryngology, so medical professionals can dispense these molds with complete clinical confidence.
- Economical and Adaptable for Growing Ears: Because you can mix and cure the material in minutes for a fraction of the lab cost, it is incredibly affordable to replace or resize a child’s swim plugs mid-season.
- Vibrant Compliance & Color Selection: Available in a spectrum of vibrant, kid-friendly colors (and skin tones) to maximize pediatric compliance. Easily mix contrasting colors so parents and patients can instantly distinguish left and right at a glance.
The Original EAR BAND-IT®
The perfect clinical companion for pediatric swim plug fittings. This comfortable neoprene headband keeps custom earplugs securely locked in place during high-activity swimming, providing an extra layer of defense for children with ear tubes or recurring ear infections. Available in Small, Medium, and Large.
Color Choices: Royal Blue, Teal, Magenta, Red, and Purple.
CUSTOM HEARING PROTECTION & REVENUE EXPANSION
Expand Your Practice. Monetize the Industrial and Recreational Markets.
Don’t limit your clinic to traditional hearing aids. With Insta-Mold Featherweight, you can easily tap into a highly profitable, volume-driven market by providing OSHA-compliant workplace safety solutions and premium recreational protection—made in your office or on-site at your customer’s facility.
Core Provider Benefits
- High-Volume B2B Contract Potential: Local plants, fabrication shops, and industrial facilities are required by OSHA to protect their workforce, but managing lab-manufactured molds for hundreds of employees is a logistical nightmare. Because the material cures in minutes, you can protect an entire shift of workers on-site at your customer’s facility with zero turnaround delays—winning lucrative corporate contracts with single-session, turn-key fittings.
- Certified Performance for Easy B2B Enrollment: Featherweight is strictly tested in accordance with ANSI Standards (S3.19-1974) at an independent, NVLAP-accredited acoustics laboratory. You can approach corporate clients with total confidence, offering a fully compliant, verified liability shield.
- Capturing the Passionate Recreational Market: Recreational shooters, motorcyclists, and motorsports enthusiasts willingly pay a premium for high-quality gear. Because Featherweight can be modified or trimmed flush right at your desk, you can craft ultra-low-profile plugs that fit perfectly beneath tight racing or tactical helmets without breaking their seal.
- Dual-Option Versatility (Solid vs. Acoustic Filters): Dispense solid custom plugs for maximum absolute noise attenuation, or integrate specialized acoustic communication filters—serving hunters, musicians, and plant supervisors who require impulse noise defense while maintaining vocal communication and situational awareness.
Full Industrial Customization Options (B2B Upsell Panel)
When you service corporate accounts, industrial safety managers look for specific compliance features. The Featherweight system scales to meet strict workplace mandates:
- Available in a Variety of Colors: Personalize colors for team identity, and use a different color each year to track earplug age at a glance.
- Metal-Detectable Options: Perfect for food processing plants and manufacturing lines where automated scanners must detect and intercept foreign objects.
- Radio & Comm Integration: Tube or combine custom molds with communication receivers for plant supervisors, dispatchers, and security teams who need clear audio feeds in loud environments.
- Loss Prevention Upgrades: Easily integrate high-strength security cords and attachment anchors right at the fitting chair.
Available in Ten Vibrant Colors
Featherweight custom earplugs and earmolds are available in ten vibrant colors—let each team member personalize their pair, or use a different color each year to track age at a glance:
Color Choice Specification (online orders): Skin Tones: Tan, Brown, Black. Neon: Blue, Orange, Yellow, Red, Green, Pink, Purple. If no color is specified, Tan will be supplied automatically.
TURNKEY PRODUCT OFFERINGS
Professional Starter Kits
All Featherweight kits include equal amounts of colored Part ‘B’ and white catalyst Part ‘A’ compounds.
The Featherweight Ear Mold Kit
Configured for hearing health professionals to craft permanent, immediate custom earmolds for BTE hearing aids right in the office, eliminating lab wait times entirely.
Medium (8 oz. Kit)
Large (16 oz. Kit)
Kit Contents: Premium Featherweight Silicone Compound, 1 Set of Measuring Spoons, 1 Bottle of Specialized Hand Lotion, 1 Core Drill, 1 Plunger, 1 Tube Threader, 25 Pre-bent “Lock” Tubing Pieces, 1 Large 3 oz Bottle of Clear-Seal Silicone Coating, 1 Dipping Cup, and Dur-A-Sil Equal Mini-Paks.
The Featherweight Ear Protection Starter Kit
Designed for practitioners focused on on-the-spot or in-office high-performance noise protection for industrial employees and recreational clients.
Medium (8 oz. Kit)
Large (16 oz. Kit)
Kit Contents: Premium Featherweight Silicone Compound, measuring spoons, hand lotion, clear-seal coating, dipping cup, protective cases, and safety attachment cords.
The Featherweight Multi-Color Starter Kit Series
Formulated with a wide array of vibrant neon choices to quickly build same-day custom solutions for multi-color water isolation (swim plugs) and pediatric compliance.
Multi-Color Starter Kit (16 oz. Kit)
Multi-Color Starter Kit – Deluxe (16 oz. Kit)
Kit Contents: 8 Jars of Part B Colored Silicone Compound (1 oz each: Red, Blue, Green, Orange, Purple, Yellow, Pink, and Tan), 2 Large Jars of Part A Activator (4 oz each), 2 Sets of Measuring Spoons, 1 Bottle of Specialized Hand Lotion, 1 Large 3 oz Bottle of Clear-Seal Silicone Coating, 1 Dipping Cup, 25 Sets of Anchors and Cords, and 50 Durable Earplug Storage Pouches.
Professional Refill & Bulk Packs
Silicone mixes only—for practices that already own tools and modification accessories and only require material replenishment.
Featherweight Mix – Medium (8 oz.)
Featherweight Mix – Large (16 oz.)
Featherweight Multi-Color Silicone Mix (16 oz.)
Kit Contents: Premium Featherweight Silicone Compound (Part A + Part B), sized to the selected kit.
The Professional Accessories & Supplies Suite
A seamless catalog for rapid supplies re-ordering.
A. Finishing, Sealing & Skin Care
- Clear-Seal Silicone Coating (Small 1 oz / Large 3 oz) | Item #7001CS / #7002CS – Tightens an earmold’s fit, adds size to a growing child’s plug, and eliminates acoustic feedback.
- Dipping Cup | Item #7040 – Companion accessory for precision coating application.
- Specialized Hand Lotion | Item #7003 – Used before kneading and mixing compounds to prevent skin oils from altering the silicone cure.
B. Clinical Preparation & Impression Tools
- Deluxe Silicone Syringe | Item #7014 – Smooth, continuous injection of mixed compounds directly into the ear canal.
- Measuring Spoons | Item #7015 – Ensures precise, equal volumetric measurement of Part A and Part B.
- Halogen Ear-Lite & Disposable Ear-Lites | Item #7010 / #7032 – Premium illumination for precise otoscopy and safe block placement.
- Foam Blocks & Cotton Blocks | Item #7009OTO / #7009CB – Canal blocks to protect the tympanic membrane (Cotton 50/bag; Foam S, M, L).
- Dur-A-Sil Equal Mini-Paks | Item #5010 – High-precision VPS clinical impression packs.
C. Precision Modification & Venting Tools
- The 3-Piece Modification Tool Set | Item #7027-ToolSet – Combo block: 1 Core Drill, 1 Plunger, and 1 Tube Threader.
- Core Drill | Item #7022 – Bores sound channels and vents into cured silicone.
- Plunger | Item #7023 – Cleanly removes silicone cores during drilling.
- Tube Threader | Item #7024 – Pulls acoustic tubing smoothly through newly drilled sound bores.
- “Lock” Preformed Tubing (13 Double Wall) | Item #7025 – Locks securely into earmolds (25 pack).
- 4″ Quilled Tubing | Item #7026 – Premium raw acoustic extension tubing (per unit).
- Flame Shaped Burr & Blue Finishing Stone | Item #7034 / #7036 – Grinding bits for contouring, shaping, and smoothing excess edge material.
D. Patient Care, Compliance & Upgrades
- Premium Ear Plug Storage Pouches | Item #7005 – High-visibility fabric cases in Blue and Black.
- Acoustic Filters | Item #7033 – Attenuate harmful noise while preserving vocal communication.
- Screw-In Anchors & Cords | Item #7018 – High-strength security retention cords, customizable by color.
Request a Starter Kit or Schedule a Practice Consultation.
Bring the lab to your fitting chair. Add Featherweight Instant Silicones to your practice and start delivering same-day ear solutions.