A method of manufacturing a custom elastomeric earmold with a secondary material infusion and said custom elastomeric earmold is disclosed. The method can include establishing a representation of a shape of the ear concha, the outer canal and the inner ear canal cavity. The method may further include casting a custom shaped injection mold. The injection mold may be used to cast a custom shape of the inner and outer ear from an elastomeric material such as silicone or urethane. An additional injection step can be performed to infuse foam into the interior of the elastomeric material.
