What Are Custom Earplugs Made Of, and Why Does Softness Matter?

Most Big Ear custom earplugs are made from platinum-cure silicone, a soft, flexible material we shape from impressions of your own ears. Softness matters because the way a plug feels decides whether you keep it in. Comfort research reviewed by a NIOSH scientist ties softer, smoother, rounder earplugs to better comfort, and comfortable protection is the kind that gets worn.

Quick answer

• Material: Most of our custom earplugs are hand-built in the USA from platinum-cure silicone, made from impressions of your ears.
• Softness: We describe softness with the Shore A hardness scale. Lower numbers are softer.
• Our range: Full Stop Super-Soft is Shore A 25, The One is Shore A 35, and the semi-soft Guardian Vanquisher is Shore A 45.
• Why it matters: NIOSH calls comfort “the key to consistent use” of hearing protection.
• Not sure? Use Find my pair or call (719) 271-4528.

What are custom earplugs made of?

At Big Ear, most custom earplugs start as two impressions of your ears and finish as platinum-cure silicone plugs, hand-built in our lab in Blythewood, South Carolina. Each plug is shaped from your impressions, so it follows your canal instead of asking your canal to follow the plug.

Our Full Stop Super-Soft and The One are made in platinum-cure silicone that is hypoallergenic and antibacterial. The Guardian Vanquisher uses a firmer, semi-soft silicone, for reasons we’ll get to in a minute.

You may see other words used for earplug materials online. We say “platinum-cure silicone” because it describes what we use. It’s soft, it holds its shape, and it can be made in any color or swirl on the Super-Soft, which is a nice bonus when you’re trying to find a pair on the nightstand.

What does “platinum-cure” mean?

Silicone starts as a liquid and has to set, or “cure,” into a solid. “Platinum-cure” names the way our silicone sets: a platinum-based curing system turns the liquid into a flexible solid that keeps its shape.

For you, the practical part is simple. The plug comes out of our lab soft and flexible, and it holds the shape of your ear.

What is Shore A, and which number is softer?

Shore A is a hardness scale used for soft, rubbery materials. The lower the number, the softer the material feels when you press on it. It’s a handy way to compare plugs without needing to squeeze every one of them.

Here’s how our main custom earplugs compare. Prices are today’s prices on our site.

Notice the pattern. Our softest plug is built for long, quiet hours, and our firmest is built for the loudest jobs. Each number is a choice about where the plug will spend its day.

Why does softness matter in your ear?

Because your ear canal is sensitive, and you’ll feel any plug that presses where it shouldn’t. A review of hearing protector comfort by NIOSH researcher Rickie Davis, published in Noise & Health in 2008, gathered the research on what makes earplugs comfortable. One study it describes found that plugs people perceived as softer, rounder, smoother, looser and shallower were rated as more comfortable (Davis, 2008).

The same review calls comfort probably the most important factor in whether workers accept hearing protectors and wear them over the long term. NIOSH says it plainly on its hearing protection page: comfort is “the key to consistent use” (NIOSH).

That’s the whole reason we care about Shore numbers. A plug that sits in a drawer protects nobody. A plug that feels good enough to forget about does its job every time you put it in.

Is the softest earplug always the best choice?

Not always, and NIOSH agrees that comfort is personal. Its guidance says no single protector will be the most comfortable for every worker (NIOSH).

Research backs that up. In a 2018 study in Noise & Health, 49 people tried four types of earplugs, and their favorite wasn’t decided by how much sound each plug blocked. How easy a plug was to put in, and how plugged-up it made the ear feel, were linked to which type people preferred. The authors concluded that choosing hearing protection should be personalized, weighing the wearer’s well-being as well as the attenuation (Samelli et al., 2018).

So we match the material to the job:

• Sleeping or all-day quiet: Super-Soft. It’s the plug you can lie on, and it suits adults and children.
• Hearing people while noise stays down: The One. Pick 25 or 30 dB filters for firearms, motorcycles, tunnel skydiving, around aircraft and marching band, and 9 to 20 dB filters for quieter settings.
• The loudest, hardest-working days: The semi-soft Guardian Vanquisher, NRR 37 dB.

How does Big Ear make sure the fit feels right?

It starts with your impressions. Every order includes a free Home Impression Kit. It arrives in 3 to 4 business days, and making the impressions takes about 15 to 20 minutes at home with a helper and our guided video. Return postage is paid, and if an impression doesn’t come out right, we send you another kit at no charge. Read the step-by-step on the Home Impression Kit page.

Once your impressions reach our lab, we build your pair by hand in 40 business days. Order shipping is $10. We keep your impressions on file for up to ten years, so a future pair or a different style can come from the same impressions. A big change in weight, or 7–10 years, can mean it’s time for a fresh set.

Every pair is backed by our 30-Day Fit Warranty. If something doesn’t feel right, tell us within 30 days of delivery and we’ll make it right. There’s also a 1-year manufacturer defect warranty against manufacturing defects (it doesn’t cover loss). Because each pair is made for your ears, custom products can’t be returned, which is exactly why we stand behind the fit.

For more on comfort, see our post on why comfort decides whether hearing protection works, and for care and replacement, how long custom earplugs last.

Should an earplug ever hurt?

No. The NIDCD says wearing earplugs shouldn’t be painful, that the plugs should feel comfortable and secure, and that you should never force them into your ears. It also notes you may need a little practice for a comfortable, secure fit (NIDCD).

If a new custom pair feels tight in one spot, give us a call. That’s what the 30-Day Fit Warranty is for. If you have ear pain, an ear infection, ear tubes, a recent ear surgery, a sudden change in your hearing, or ringing that is new or getting worse, please see a doctor or audiologist before wearing any earplugs.

Frequently asked questions

Are Big Ear earplugs hypoallergenic?

The platinum-cure silicone we use for the Super-Soft and The One is hypoallergenic and antibacterial. If your ear gets sore or irritated, stop wearing them and check with a doctor or audiologist.

Which Big Ear earplug is the softest?

Full Stop Super-Soft, at Shore A 25. It’s NRR 32 dB and $168.95, and it’s made for adults and children.

Why is the Guardian Vanquisher firmer?

It’s built for very loud and high-impact work, with an NRR of 37 dB. It’s a semi-soft silicone at Shore A 45, a little firmer than our other custom plugs.

Can kids wear Super-Soft earplugs?

Yes. Super-Soft is made for adults and children. Our post on protecting your kids’ hearing covers when earmuffs may be easier for little ones.

Can I pick a color?

Yes, the Super-Soft comes in any color or swirl.

Ready for a softer fit?

The easiest way to start is with the free Home Impression Kit that comes with your order. If you’d like help choosing between Super-Soft, The One and the Guardian Vanquisher, try Find my pair, or call us at (719) 271-4528. We’re happy to talk ears.

Sources

• Davis RR. What Do We Know About Hearing Protector Comfort? Noise & Health, 2008;10(40):83–89 (CDC Stacks).
• NIOSH. Provide Hearing Protection (reviewed 31 January 2024).
• Samelli AG, et al. The Study of Attenuation Levels and the Comfort of Earplugs. Noise & Health, 2018;20(94):112–119 (PMC).
• NIDCD. Hearing Protectors (last updated 16 April 2025).