Methods and systems for designing an earpiece device are provided. The method includes receiving a plurality of images for a respective plurality of individuals. Each image includes at least one ear anatomy. For each image, a three-dimensional (3D) surface representing the at least one ear anatomy is extracted, to form a plurality of extracted surfaces corresponding to the plurality of images. At least one statistical measurement representative of at least a portion of the plurality of individuals is determined from among the plurality of extracted surfaces. At least one design parameter for the earpiece device is optimized based on the at least one statistical measurement, The earpiece device is formed using the optimized at least one design parameter.
