Hearing loss can impact quality of life, leading to social disconnection and isolation for more than 5% of the world’s population, according to health reports. One solution to this problem is the use of hearing aids, which are produced from molds custom-made for the patient’s ear. In the Brazilian scenario, purchasing a hearing aid device can be time-consuming, mainly because of all the processes involved. For pre-molding, for example, a modeling compound is injected into the patient’s ear canal to obtain a model of the ear and develop the mold for the hearing aid. This is a very uncomfortable process and can lead to errors depending on the patient’s cooperation and the professional’s experience. In this scenario, an opportunity for improvement arises, which is the use of 3D scanning in conjunction with additive manufacturing to obtain a 3D model of the ear in CAD and the manufacture of a mold, which can lead to reduced waiting times, ease of customization, improved logistics, and increased quality of ear molds. Furthermore, the availability and growing accessibility of low-cost 3D printers make this solution particularly viable for emerging countries such as Brazil, where economic and infrastructural limitations often hinder the adoption of advanced medical technologies. These systems can democratize access to high precision manufacturing techniques, enabling local clinics and professionals to independently produce high-quality hearing aid molds.