ATLANTA, GEORGIA — Aware Defense has been awarded a five-year, sole-source Program of Record contract by the U.S. Navy’s Naval Air Systems Command (NAVAIR) Aircrew Systems Program Office (PMA-202) to provide custom hearing protection for Naval Aviation personnel.
The program will use Aware’s eFit 3D ear scanning technology to capture individual ear canal geometry and manufacture custom hearing protection and Communications Earplugs (CEP) for Naval Aviation aircrew and flight-line maintainers.
Under the contract, Aware Defense will serve as the Navy’s end-to-end source for digital ear scanning, manufacturing, and delivery of the custom-fit devices.
Scaling Custom Hearing Protection Across Naval Aviation
The PMA-202 program builds on earlier work between Aware Defense and the Navy. From September 2025 through July 2026, the company conducted on-site ear scanning events around the country and delivered 6,373 custom-fit devices while working with NAVAIR Aeromedical Safety Officers and Navy audiologists.
Under the expanded program, Aware plans to scale production and delivery to 42,000 custom-fit units beginning August 1, 2026, serving Naval Air Stations in the United States and overseas.
A soldier undergoes 3D ear scanning. Image credit: Aware
Aware’s eFit system uses non-contact optical 3D scanning and radial illumination to capture the geometry of the ear and ear canal beyond the second bend. According to the company, the system provides dimensional accuracy of less than 90 microns.
“We are honored to be chosen as the sole-source supplier for this critical program to deploy custom hearing protection built from each warfighter’s unique ear anatomy using Aware’s patented 3D ear scanning technology,” said Sam Kellett, Jr., Chief Executive Officer of Aware.
“Hearing loss is one of the most common service-connected disabilities, and it is preventable. Because every ear is different, our eFit scanner and advanced additive manufacturing deliver precision-built protection and communications for mission-critical environments, custom fit at scale. This award reflects the U.S. Navy’s commitment to preventing hearing loss and sets a new standard for protecting the warfighter.”
The company says its process is designed to allow large numbers of personnel to be scanned on location and subsequently receive individually manufactured devices. Aware reports that its team has previously scanned 700 personnel over five days and delivered the resulting custom-fit devices within 60 days.
“Aware Defense is ready to execute at fleet scale,” said Stu Booker, President of Aware Defense. “We are proud to continue our partnership with the Navy to accelerate the fielding of advanced hearing protection. We know that gear that fits gets worn, and every ear scan and custom-fit device advances our mission to protect warfighters and preserve long-term hearing health. Our team has proven its ability to seamlessly scan 700 personnel in five days and have precision-fit devices in the warfighters’ ears within 60 days, enabling rapid program expansion across Naval Aviation.”
The program is intended to expand access to individually fitted hearing protection while supporting communications and hearing conservation among Navy aviation personnel.
About Aware
Aware Custom Biometric Wearables is the parent company of Aware Defense and develops custom in-ear devices for hearing protection, communications, and biometric monitoring using 3D ear scanning technology. Aware Defense is led by retired Department of Defense military personnel and manufactures its products in the United States.
Source: Aware
