Custom-molded earplugs for high-noise work · Made in Mississauga, Canada Q
A plug that comes out to talk, or because it hurts by hour six, is not protecting anyone 11. Qui8 Db earplugs are molded from a 3D scan of each worker's own ear, 3D-printed and finished in soft silicone Q. Safety orange, so a supervisor can spot them from across the floor. Filtered for crews who need to hear each other, with three DI filter levels or an impulse filter for impact noise S1S3; unfiltered where the noise is highest. Built to last multiple years, not a shift Q.
Start here
If you run the plant
A protector that comes out for five minutes an hour gives less than half its rated protection 11. Custom costs more up front and is cheaper than foam from year 3 in the base case 202526.
If you own the safety file
The regulation does not name a protector type. It requires selection based on measured exposure, with records and training 12. Fit testing is still recommended for custom plugs 1220.
If you work the floor
Custom-molded plugs were rated most comfortable of nine earplug types in a six-week field survey 13. The filtered option is designed so speech and warning signals still get through 2629.
On the floor · Filtered vs unfiltered · What the filter colours mean · Crew questions
01 · Why now
WorkSafeNB describes noise-induced hearing loss as the most common permanent work-related disease in Canada 6. Ontario's Ministry of Labour is running a noise inspection campaign until March 31, 2027 1.
Regulation
Under O. Reg. 381/15, employers must take every reasonable measure to protect workers from hazardous sound and make sure no worker is exposed above an 8-hour equivalent of 85 dBA 2. Workplaces under federal rules have an 87 dBA limit 30.
Inspection
Previous noise exposure assessment reports, details of how you selected control measures, hearing protection selection records, and training records 1. Selection must be based on the actual noise levels workers are exposed to 1. An inspector can also require a noise assessment by a qualified professional, at the employer's expense 1.
Claims
More than half of the non-fatal WSIB claims accepted in IHSA-served industries from 2012 to 2021 were for noise-induced hearing loss 7. An allowed claim can cover hearing aids every five years, repairs and maintenance, loss-of-earnings benefits and permanent-impairment benefits 8.
A Quebec cohort study of 46,550 male workers found that people working in ambient noise of 100 dBA or more had 2.36 times the risk of a work-related injury that led to a hospital stay. Risk also went up about 1% for each decibel of hearing loss 9.
A systematic review and meta-analysis found injury risk rose 22% for every 5 dB increase in noise exposure, and the most exposed groups (above 90 to 95 dB) had 2.16 times the risk of the least exposed 10.
Earplugs are the last line, not the first. Ontario requires engineering controls and work practices first; hearing protection is used only where those do not exist or are not reasonable 1.
Data: Girard et al. 2015 9; Dzhambov & Dimitrova 2017 10. Reference = unexposed / least-exposed group (1.0).
02 · Wear time
An estimated 37% of Canadians aged 19 to 79 (9.2 million) experienced tinnitus in the past year 5. Among noise-exposed men classed as "vulnerable," 54% had experienced tinnitus, compared with 39% of people who had never worked in noisy environments 4. The fix is not a higher number on the box. It is a plug that stays in.
Data: CCOHS, Hearing Protectors 11.
Pull a 25 dB plug out for five minutes an hour and it protects like an 11 dB plug. Ten minutes, and it is an 8 dB plug 11. A quick word with a coworker, a phone call, a scratch: that is where the protection goes.
That is why NIOSH calls comfort "the key to consistent use of hearing protection," and warns that "hearing protectors that workers do not wear are not a good investment" 12. Comfort is not a perk. It is the control.
In a 6-week field survey of 118 participants testing nine earplug models, custom-moulded earplugs were rated best for overall comfort and for every dimension of comfort measured: acoustic, physical, functional and psychological.
Terroir, Perrin & Wild, Ergonomics, 2022 13
03 · Why custom
NIOSH defines custom earplugs as devices that "use an impression of the worker's ear to make a device uniquely fitted to that person" 12. Ten things that changes: five for the crew wearing them, two for the supervisor checking them, three for the safety file.
For the crew
In a six-week field survey, custom-moulded earplugs scored better than roll-down foam and premolded earplugs on overall comfort and on all four comfort dimensions measured 13. Comfort drives wear time, and wear time drives protection 1112.
For the crew
NIOSH says foam earplugs "are not a good choice for intermittent use at dirty worksites because they must be rolled with fingers before insertion" 12. A custom plug is already shaped to the ear: wipe it, seat it, back to work Q.
For the crew
Earmuffs and canal caps can interfere with hardhats, helmets, respirators, eye protection and some eyeglasses 12. Glasses can break an earmuff's seal and reduce protection 11. CCOHS describes earplugs as convenient to use with other PPE 11.
For the crew
NIOSH: "Earplugs are lightweight, easy to store," while "earmuffs are heavier than earplugs and may be uncomfortable in warm places" 12. CCOHS adds that earplugs are more comfortable for long wear in hot, humid areas 11. Qui8 Db molds are lightweight Q.
For the crew
Researchers note that "a common complaint after a work-shift in high noise levels is fatigue," where listening to other people takes more effort 24. Qui8 Db is designed to reduce hearing fatigue after a long workday through a comfortable custom fit and attenuation matched to the job, not more than the job needs Q1321.
For the supervisor
CCOHS lists "more difficult to see and monitor usage" as a drawback of earplugs 11. One manufacturer's data sheet notes that a very bright orange plug "makes compliance checks easy and quick" 28. Every Qui8 Db mold is safety orange, with no colour options to manage Q.
For the supervisor
NIOSH notes that custom earplugs cost more at the outset but "are more durable and last longer than formable or preformed earplugs" 12. Custom silicone earplug makers quote 3 to 5 years with proper care 27. Qui8 Db molds are built to last multiple years Q. One pair per worker, not a dispenser to keep stocked.
For the safety file
Custom earplugs are usually made of acrylic, vinyl or silicone. Acrylic is "hard and brittle," and vinyl or silicone are recommended for long periods of wear 20. Qui8 Db uses silicone Q.
For the safety file
More blocking is not always better. The UK HSE says protectors that reduce sound at the ear to below 70 dB should be avoided because over-protection can make communication and warning signals harder to hear, and can push workers to take protection out 21. NIOSH says to aim for 75 to 85 dBA at the ear 12. The filtered Qui8 Db option is designed for this range Q.
For the safety file
Derating is the discount regulators apply to a lab rating to estimate real-world protection. Germany's scheme takes only 3 dB off custom earplugs, compared with 5 dB for earmuffs and 9 dB for formable (foam) earplugs. France's proposed scheme takes 5 dB off custom earplugs and 10 dB off foam 18. Canada's CSA Z94.2 does not have a separate custom category; it credits 50% of the NRR for all earplugs 3.
On the floor
Filtered (and which filter level) or unfiltered is chosen from each area's measured exposure, not from the trade 1. Workplace photographs are illustrative.
Concrete breakingImpulse and impact noise
Service bayAir tools, stop-start
Wood shopSaws, all shift
Bottling lineSteady noise, teams who talk
04 · Custom vs every other type
Five common types of hearing protection, compared on the factors that decide whether protection actually reaches the ear. Each cell is sourced, so the row you need can go straight into your hearing protection selection record 1.
| Factor | Qui8 Db custom silicone | Roll-down foam | Pre-formed / premolded | Canal caps (banded) | Earmuffs |
|---|---|---|---|---|---|
| How it fits | Made from an impression of the worker's own ear 12 | Foam expands to the contour of the canal 12 | Pre-shaped "to fit most ears" 12 | Covers the canal entrance, held by a lightweight band 12 | Surrounds the outer ear; headband or hardhat-mounted 12 |
| Comfort (field survey) | Rated best overall and on all four comfort dimensions 13 | Not significantly different from premolded on many characteristics 13 | Generally preferred to foam 13 | Not included in the survey 13 | Not included in the survey 13; "may be uncomfortable in warm places" 12 |
| Dirty hands / insertion | Pre-shaped; no roll-down step Q | Must be rolled with fingers; poor choice for intermittent use at dirty sites 12 | Easier to take off and put on for stop-start noise 12 | Easier to take off and put on for stop-start noise 12 | Easier to take off and put on; often easier to fit properly 12 |
| Durability | More durable, lasts longer than formable or pre-formed 12; 3 to 5 years typical 27 | Disposable; costed at 10 pairs per worker per week 20 | Reusable; costed at 2 pairs per worker per month 20 | No comparable data located | Generally more durable than plugs; replaceable parts 11 |
| Weight / heat | Lightweight 12Q; better for hot, humid areas 11 | Lightweight 12 | Lightweight 12 | Lightweight band 12 | Heavier; less comfortable in hot work areas 1112 |
| Other PPE / glasses | Convenient with other PPE 11 | Convenient with other PPE 11 | Convenient with other PPE 11 | Can interfere with hardhats, respirators, eyewear 12 | Glasses can break the seal; may interfere with headgear 1112 |
| Supervisor visibility | Safety orange on every mold Q | Earplugs are "more difficult to see and monitor usage" 11; bright colours help compliance checks 28 | "Easily seen at a distance" 11 | ||
| Fit consistency | Attenuation depends on canal depth captured at impression 20; fit testing recommended 12 | Depends on insertion skill; training improves results 18 | More prone to loosening or falling out over a shift 18 | No comparable data located | Less attenuation variability between users 11 |
| Annual cost per worker (US model, 2018) | US$50 (US$150 pair, 3-year life) 20 | US$48 to $72 20 | US$14.30 to $19.80 20 | Not modelled in source | Not modelled in source |
Scroll horizontally on smaller screens. "No comparable data located" means no source was found for that cell; it is not a negative finding. The US cost row is from a 2018 manufacturer model and is shown for comparison only; the Canadian figures used on this page are in the cost section below.
Data: Murphy et al., derating schemes by country 18. North American schemes (CSA, NIOSH, OSHA) do not have a separate custom category; see note below.
Data: NIOSH Advanced Hearing Protector Study, GM Flint Metal Center 16. Device was a semi-custom earplug with selectable filters.
Data: Sayler et al., Ear and Hearing, 2019; 91 workers, 251 fit tests. SD 6.4 dB (custom) and 7.4 dB (non-custom); difference not statistically significant 14.
05 · Choose the filter
Ontario requires protection to be chosen based on the actual noise workers are exposed to and how much the device reduces it 1. Every Qui8 Db plug is scanned and printed to the wearer's ear. What changes is the filter that snaps into it. Pick a level from the measured noise in each area, not from the trade on the badge, and change the filter later without changing the mold Q. Filters are sold in pairs and are colour-coded by attenuation, so a supervisor can read the level from across the floor S3Q.
Three colour-coded levels, 20 to 30 dB. Flat response in the speech range so leads and forklift operators keep talking; a steep cut from about 4 kHz against the high-frequency noise that wears a crew down by hour eight S3.
A valve filter that reacts to peak-impulse noise: nail guns, drop hammers, riveting, gunfire. Open and vented between hits, so the wearer hears where sound is coming from. Lab-tested through thermal shock, humidity and sand S1.
For the loudest areas (presses, grinders, compressors), where blocking the most noise the plug can block is the priority. No filter, no vent, same custom fit Q.
Flat attenuation from 10 to 25 dB that lowers the volume without muffling the mix. Built for stage, pit and front-of-house S2. Own page.
The mold is the fit. It is printed from a scan of your ear, finished in soft silicone, and it is what seals the canal and keeps the plug comfortable for a full shift Q. The filter is the acoustics. It is a small insert that snaps into a channel through the mold and decides how much sound passes, and which frequencies S1S2S3Q. An unfiltered plug has no channel and blocks the most it can Q.
DI series
Most industrial noise peaks in the high frequencies: the whine, hiss and shriek of tools, air and metal. The DI filter is shaped for that profile. It attenuates evenly through the low and mid range, where speech lives, then ramps up from about 4 kHz to screen out the harsh high-frequency sound that leaves a crew drained at the end of a shift S3. The result is protection that does not isolate the wearer S3.
Each DI filter is ventilated. A channel lets air move into the ear canal all day, which reduces pressure, limits the build-up of moisture and sweat, and takes the edge off the occlusion effect, the hollow echo of your own voice that makes people pull a plug out to talk S3. A plug that stays comfortable stays in, and the rating on the box only counts while it is in 11.
Over-protection is a real problem. A worker who cannot hear a forklift horn or a lead's instruction takes the plug out, and an unprotected minute costs more than a few decibels of margin 1121. Three levels let you match each zone instead of issuing the loudest plug to everyone S3Q.
| Filter | Attenuation | Where it fits | Typical areas |
|---|---|---|---|
| Yellow | 20 dB | Moderate noise with high communication needs S3 | Lead hands, forklift and tow-motor operators, maintenance, shipping and receiving Q |
| Red | 25 dB | Standard industrial environments S3 | Assembly, packaging, machining cells, bottling and canning lines Q |
| Purple | 30 dB | Heavy machinery and extreme noise zones S3 | Stamping, grinding, compressor rooms, saw lines Q |
Attenuation figures are supplier-stated single values S3. Select the level from your measured Lex,8 for each area, apply the derating your program uses, and record the choice in your hearing protection selection record 31.
SPEC Sold in pairs S3 · Three attenuation levels S3 · Vented acoustic channel S3 · Fits the Qui8 Db custom mold, filtered configuration Q · Swappable without a new mold Q
DI Impulse
Steady noise is one problem. A nail gun, a drop hammer, a rivet gun or a rifle is another: a pressure spike that peaks and is gone before a wearer could react. The DI Impulse filter is an acoustic valve designed to respond to that spike instantly, taking the force out of the pressure wave from ballistic and impact sources S1.
Between hits, the filter stays open. An air-vented channel keeps sound moving into the ear, so the wearer keeps 360-degree directionality: which bay the forklift is in, which side the call came from. The sheet calls this situational awareness, and it is the reason an operator keeps the plug in during the work, not just during the loud part S1.
Impulse noise is treated separately from steady noise in Ontario's guidance, and dual protection may be required at the highest peak levels 312. The DI Impulse filter does not replace that assessment; it gives you a protector built for the impact profile that the assessment identifies. Record the measured peak levels beside the selection Q.
| Sector | Applications named on the sheet |
|---|---|
| Defence and law enforcement | Small-arms fire, artillery exercises, tactical entry, combat environments S1 |
| Heavy industry and construction | Pneumatic riveting, drop-hammer operations, framing with nail guns, high-impact manufacturing S1 |
SPEC Acoustic valve, impulse-responsive S1 · Air-vented channel S1 · Thermal shock, humidity and sand tested S1 · 12-hour continuous-wear rating S1 · Washable S1 · Fits the Qui8 Db custom mold Q
| Series | Filter | Attenuation | Response shape | Vented | Pick it for |
|---|---|---|---|---|---|
| DI | Yellow | 20 dB | Flat low, steep cut from about 4 kHz | Yes | Moderate industrial noise where talking matters S3 |
| DI | Red | 25 dB | Flat low, steep cut from about 4 kHz | Yes | Standard industrial environments S3 |
| DI | Purple | 30 dB | Flat low, steep cut from about 4 kHz | Yes | Heavy machinery and extreme noise zones S3 |
| DI Impulse | Impulse | Impulse-responsive valve; no single figure on the sheet | Open between hits, closes on the pressure spike | Yes | Gunfire, artillery, nail guns, drop hammers, riveting S1 |
| Unfiltered | Solid | Maximum the mold provides | Solid, no acoustic path | No | Presses, grinders, compressor rooms; the loudest areas Q |
| DM | Ocean to Black | 10 to 25 dB | Flat across the spectrum | Yes | Musicians, DJs, crews and concertgoers: see the musicians page S2 |
The DI figures and the DM figures are from different supplier sheets and were not measured together. Use the measured noise in each area, the derating your program applies and the protector's full attenuation data to make the selection S1S2S33.
Not sure which level an area needs? Send us the readings from your last noise assessment and we will mark up a filter per zone before impression day Q.
Match filters to my noise map
06 · Impression day
3D scanning and printing are now standard in custom ear products. A US International Trade Commission briefing describes the hearing aid industry as having shifted "nearly exclusively" to additive manufacturing, and notes that Starkey 3D-prints 98% of its hearing aids 23. The same method makes a Qui8 Db mold Q.
Qui8 Db comes to your location, or workers visit an approved hearing clinic Q. Impressions should be taken by an experienced professional, because impression quality is critical to fit and to how much noise the plug blocks 20.
Each ear is captured digitally Q. In a clinical comparison, participants rated 3D ear scanning as more comfortable than traditional impressions, and preferred it 22.
Molds are 3D-printed and finished in safety-orange silicone, 100% in Mississauga, Canada Q.
Pairs arrive filtered (DI level or DI Impulse) or unfiltered, as specified per worker Q. NIOSH recommends fit testing to confirm each worker gets enough noise reduction 12.
Data: Zheng, Didion & Ferguson, Bioengineering, 2023; 12 adults, p = 0.01 22.
07 · Cost over five years
A Honeywell cost model notes that the high upfront cost of custom earplugs "may be offset to some degree by their longevity," and that long-term cost depends on remakes, lost plugs and staff turnover 20. The grid below uses published Canadian prices, labelled so you can see which inputs are verified listings and which are model assumptions. Nothing here is a Qui8 Db quote.
| End of year | Disposable foam | Custom, 3-yr life | Net vs foam | Custom, 5-yr life | Net vs foam |
|---|---|---|---|---|---|
| Year 1 | $8,880 | $18,000 | −$9,120 | $18,000 | −$9,120 |
| Year 2 | $17,760 | $18,000 | −$240 | $18,000 | −$240 |
| Year 3 | $26,640 | $18,000 | +$8,640 | $18,000 | +$8,640 |
| Year 4 | $35,520 | $36,000 | −$480 | $18,000 | +$17,520 |
| Year 5 | $44,400 | $36,000 | +$8,400 | $18,000 | +$26,400 |
Arithmetic: foam = 100 workers × 2 pairs × 240 shifts × $0.185 = $8,880 per year, cumulative. Custom = 100 × $180 = $18,000 at the start of each life cycle (so a second $18,000 in year 4 on a 3-year life). Not included: dispensing time, waste, fit testing, remakes, losses or turnover 20. Add those in the calculator.
Conservative
Assumes your crew uses only 1 foam pair per shift (a sensitivity assumption, half the Honeywell model 20) and custom lasts 3 years.
Foam: 100 × 1 × 240 × $0.185 = $4,440/yr → $22,200 at yr 5
Custom: 100 × $180 × 2 cycles = $36,000
Break-even: not within 5 years. In this case the argument for custom is wear time and comfort, not purchase cost.
Moderate (base case)
Assumes 2 foam pairs per shift, as in the Honeywell model 20, and a 3-year custom life.
Foam: 100 × 2 × 240 × $0.185 = $8,880/yr → $44,400 at yr 5
Custom: 100 × $180 × 2 cycles = $36,000
Break-even: year 3 (foam $26,640 vs custom $18,000). The grid above is this scenario.
Aggressive
Assumes 2 foam pairs per shift and a 5-year custom life, the top of the range makers quote 27. No remakes or losses.
Foam: $8,880/yr → $44,400 at yr 5
Custom: 100 × $180 × 1 cycle = $18,000
Break-even: year 3. Any turnover, loss or remake allowance reduces this; set it in the calculator.
| Exposure | What the source says | Source |
|---|---|---|
| Claim volume | WSIB recorded 8,312 noise-induced hearing loss claims in 2025 | 1 |
| Claim benefits | Hearing aids every five years, repairs, maintenance, batteries, loss-of-earnings and permanent-impairment benefits | 8 |
| Inspection | Inspector can require a noise assessment by a qualified professional, at the employer's expense | 1 |
| Injury risk | 2.36× risk of injury leading to hospital admission at 100 dBA or more; about +1% per dB of hearing loss | 9 |
| Non-use | "Hearing protectors that workers do not wear are not a good investment" | 12 |
08 · Straight talk
A health and safety manager will check these points before signing off, so here they are, up front and sourced.
10 · FAQ
O. Reg. 381/15 does not mandate a protector type. It requires protection chosen on the actual noise level, the device's noise reduction and the maker's information on its use and limits, with training on use and care 12. Custom plugs fit that framework like any other protector. What satisfies the regulation is your selection record, not the plug on its own.
Qui8 Db molds are built to last multiple years Q. One maker puts custom silicone earplugs at 3 to 5 years with proper care 27. Useful life varies with the work environment, the wearer's body and how the plugs are cared for 20. The cost model on this page uses 3 years as the conservative case.
That is what the filtered option is for. An acoustic filter lets speech pass while keeping the overall noise level lower 26. Avoiding over-protection (below 70 dB at the ear) helps workers hear warning signals 21. For the loudest areas, specify unfiltered and follow the dual-protection guidance 123.
Yes. Qui8 Db comes to your location, or workers can have impressions taken at an approved hearing clinic Q.
Yes. NIOSH recommends fit testing to make sure the chosen protector gives enough noise reduction 12, and the Honeywell brochure calls fit testing necessary for custom earplugs 20. Treat it as part of the program, not an extra.
Yes. Every mold takes any DI filter, so a lead hand in Yellow, an assembler in Red and a grinder operator in Purple all wear the same product with different inserts S3Q. Choose per area from your noise map and record it in the selection record 31.
Swap the filter. The mold does not change Q.
The DI design keeps attenuation flat through the low and mid frequencies, where speech and most alarms sit, and ramps up from about 4 kHz S3. Signals come through quieter, not missing. Confirm audibility of your specific alarms during the fit check 12.
Impulse and steady noise are different hazards 12. The DI Impulse filter is built for the impact profile; DI filters are built for continuous high-frequency noise S1S3. Send us the assessment and we will mark up both by zone Q.
Questions your crew will ask
In a six-week field survey of 118 participants trying nine earplug models, custom-moulded plugs were rated most comfortable overall and on every type of comfort measured 13. Qui8 Db plugs are soft silicone, not hard acrylic Q20.
With the filtered version, speech and warning signals still come through while the overall noise is lower 2629. The DI filter cuts the high-pitched noise hardest and leaves the lower range, where horns and voices are, at a more even level S3. Safety guidance says a plug that blocks too much is a problem, because people stop hearing warnings and pull it out 21.
No. A custom plug is already shaped to your ear, so there is no roll-down step Q. Foam has to be rolled with your fingers, which is why NIOSH says it is a poor choice for dirty worksites 12. Reusable plugs do need cleaning 20.
Earplugs sit inside the ear, so they do not clash with hard hats, respirators or glasses the way muffs and banded caps can 1211. Glasses can break the seal on earmuffs 11; a plug sits inside the ear, clear of the frames.
Each ear is scanned with a 3D scanner Q. In a clinical comparison, people rated the scan more comfortable than a traditional impression and preferred it 22. Your pair is then 3D-printed and finished in silicone in Mississauga, and comes back in safety orange, filtered or unfiltered as chosen for your role Q.
A plug rated at 25 dB gives only about 17 dB if it is out for one minute an hour, and 11 dB if it is out for five 11. Working in 100 dBA or more was linked to 2.36 times the risk of an injury serious enough for a hospital stay 9.
The vent. Air moves through the filter, so your voice is not sealed inside your head the way it is with a solid plug S3.
Next step
Tell us how many people work in noise and where. Qui8 Db will plan impressions at your plant or at an approved hearing clinic Q.
Bibliography
Every numbered citation on this page points to one of 34 entries: Ontario regulations and guidance, Statistics Canada, CCOHS, NIOSH, the UK HSE, peer-reviewed studies and manufacturer documents, plus the Qui8 Db specifications marked and the acoustic filter supplier's sheets marked to . Tell us who you are and we will email you the full list.
