GN ReSound Hearing Aid Impact Simulation with Abaqus FEA
Case study showing how GN ReSound used Abaqus FEA to simulate drop impacts on hearing aids, redesign rubber suspensions, and reduce receiver g-forces from 15,000g to 11,000g.
GN ReSound applied realistic simulation with Abaqus/Standard and Abaqus/Explicit to model rubber suspension behavior and predict peak g-forces on hearing aid receivers during drops. High-speed video and physical pendulum tests validated the models. Engineers then iterated rubber tab designs to constrain receiver movement, achieving consistent force reduction below the 14,000g damage threshold while maintaining vibro-acoustic stability through Tosca optimization.
Abaqus FEA replaced trial-and-error testing with predictive impact analysis for miniaturized hearing aids.
Simulation of rubber suspension shrink-fit and 2-millisecond drop events identified 15,000g peak forces exceeding the 14,000g receiver limit.
Validated models enabled iterative redesign that lowered impact forces to 11,000g using added rubber tabs.
Tosca structural optimization improved vibro-acoustic stability of rubber components alongside mechanical robustness.
Simulation became a permanent step in every new product development project, shortening time-to-market.
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