I engineered an ergonomic, reusable earplug system and protective travel case designed for acoustic comfort and portability. Using CAD, I developed multi-flanged silicone tips paired with an acoustic attenuation core and a compact, snap-latch carrying case. I applied strict DFM principles for liquid silicone rubber (LSR) molding and thin-wall plastic injection, optimizing draft angles and seal tolerances. The deliverable included production-ready technical files and photorealistic 3D renders showcasing soft-touch textures and matte finishes