Seki, founded by Chris Ryan, set out to protect surfers from exostosis, or “surfer’s ear,” a bony growth in the ear canal that can cause hearing loss, across markets in the USA, Europe, Japan, Australia, and New Zealand. They aimed to develop an earplug that prevents water entry while allowing sound for situational awareness, enhancing safety and comfort for water sports enthusiasts.

Globex partnered with Seki to design the SEKI earplug, a protective solution for surfers, within a tight 3-month timeline before manufacture. The team used an iterative, consumer-led design process, creating silicone castings with 3D-printed moulds to test fit and compliance, ensuring a comfortable, one-size-fits-all design that retains in the ear during extreme conditions.

The earplug was engineered to keep water out while allowing sound in, preserving situational awareness and protecting against exostosis-related hearing loss. Weekly prototypes were tested on beaches near Auckland, a hub for New Zealand’s innovative tech scene, with rapid feedback refining the design for comfort and reliability in the waves.

Capabilities Used

• Requirements analysis and concept development

• 3D modelling / CAD design

• Product design and prototyping

• Short-run manufacturing

• LSR tooling

• Design validation

• Project management

Globex successfully delivered the SEKI earplug design to Chris Ryan, meeting all fit and performance requirements. Consequently, the earplug, which protects against exostosis while enabling situational awareness, is now shipping to surfers worldwide, enhancing safety on the water.