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Providing Quality Custom Earpieces for Over 35 Years

Custom Pilot Earpieces

With our aviation molded earpiece and our BoomBar, the Plantronics MS50 series, Starset, or Telex 5X5 Pro III can be worn without a headband. The headset literally just hangs from your ear. For those using a Telex receive-only headset (Telex PEM or PEV 77), or the Plantronics Starset, no BoomBar is needed; the earpiece simply snaps directly into the headset.

How does it work? The custom earpiece is snapped on to the BoomBar. The headset amplifier box is now slipped over the BoomBar and the plastic sound tube plugs into the headset, delivering the sound into your ear. The result: complete elimination of uncomfortable headbands during those long trips and better sound. With our custom pilot earpieces and aviation headsets, you will look professional and sound professional, even at the end of the longest duty day.

Pilot Earpieces are available in Satin Soft or Acrylic material. Both the Satin Soft and Acrylic will be comfortable, so don't go one direction or the other for more comfort. The Satin Soft is the most popular model and does tend to seal the ear a bit better so we recommend this type earpiece for noisier cockpits or for folks that are having trouble hearing ATC.

Let us send you our at-home impression kit to make a custom impression of your ear. Mail the completed impression to our lab using the mailing materials we provide, or to the address at the bottom of the lab order form.. We will return to you a custom made earpiece guaranteed to give you the comfort and convenience you have been looking for. The impression kit is sent out automatically after placement of the order.

Pilot Earpieces can be ordered in a wide variety of colors. There is even a glitter option for that personalized touch.

Clarity Aloft -  Clarity Aloft custom earpieces made from our Satin Soft material designed to replace the foam ear tips provided with aviation headsets such as the Clarity Aloft or CEP earphones. These fit all Clarity Aloft models, including the Flex. We do recommend professional deep impressions for our Clarity Aloft earpieces

Faro Air -  Faro Air custom earpieces made from our Satin Soft material designed to replace the foam ear tips provided with the earphones. We do recommend professional deep impressions for our Faro Air earpieces


Bose ProFlight Custom Earpieces -  Custom earpieces made from our Satin Soft material designed to replace the generic Bose ear tips supplied with the Bose headset. Be comfortable for extended flights with a custom set of earpieces for your Bose headset. 

These custom earpieces fit the ProFlight, and the ProFlight Series 2 headsets.

Pre-Flight Earplugs -  Pilots should also consider a set of our JB-1000 Noise Protection Earplugs for your pre-flight/walk-around. Protect your ears from damaging noise. We recommend deep impressions for Noise Protection Earplugs. We can use your deep impressions to make both your pilot earpieces, and your pre-flight earplugs

Scroll down to see available models

Price: $175.00 Order Now
Price: $24.00 Order Now

How do I order a custom earpiece?

Click on the blue Order Now button below the product offered. If placing and order for two or more earpieces, let us know if the earpieces are for the same person and same ear. If for different people, please specify the name and color for each person in the comment section before check out.

Once your order is received, we will ship an impression kit to make an impression of your ear. (or in the case of deep impressions, we will email you a Lab Order Form, see deep impression advisory). Mail the completed impressions to our lab using the postage paid mailing materials or to the address at the bottom of the lab order form. We will use your impression to make a reverse casting and return to you a custom made earpiece that will fit in your ear and are guaranteed to give you the comfort and convenience you have been looking for.

Earpieces can be ordered in a wide variety of colors. If no color is selected the earpiece will have a variable tan color. (The material does not cure perfectly clear.) There is even a glitter option for that personalized touch.

Your comfort is guaranteed, or we will
remake your earpiece for free!


I wanted to take a moment to compliment and thank them for the wonderful job that they have done in making my headset much, much more comfortable and easier to wear. The process of making impression of my ear and forming the earpiece was quick and painless. With the help of another person, I was able to get the mold made in the comfort of my own home with absolutely no hassle. Following a short waiting period, I had a new custom molded earpiece for my Plantronics MS50 headset. After using the earpiece for the last two weeks, my ear is much more comfortable, I don't have as many headaches while I'm flying due to the excess noise, and the earpiece feels great. I am actually so pleased with the way this headset turned out and the efforts of that I am looking into replacing the earbuds for my iPhone so that I can enjoy the same level of comfort at home when listening to my music and podcasts. I can without a doubt recommend Avery Sound to all of my friends and family for any sound and custom earpiece and ear plug needs. They are a great company and a pleasure to do business with.

A. Menefee IV

Brentwood, Tennessee

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Just to let you know that the headset and custom earpiece arrived safe and sound last Friday. Gave it a try out and it works fine, well worth the wait and just what is needed if you wear glasses . . . many thanks.

C. Lebioda

New York, New York

The Clarity Aloft custom ear plugs I bought from you worked great in the KingAir I flew in Afghanistan! Even better in the LearJet I'm flying now. I've recommended your company to several of my pilots.

S. Carroll


I want to thank you guys for the FANTASTIC service and products I received from your company. I ordered the aviation custom earpiece and Plantronics headset. Now that I'm using it, I can't believe I spent seven years in the 737 without it. Never again. Your reps made it simple and seamless to get the earpiece made and delivered. I had the completed product in my hands very quickly! Great products, great service. I'm a permanent customer! Thank You!!!

M. Esther

Jasper, Georgia

This really is the best earpiece I have had. Very comfortable.

D. Illig

Kingwood, Texas

I have been flying for the past 15 years as a professional airline pilot. I have used all kinds of "conventional" headsets and have always avoided the mold type for no real reason. After having an arch on my head for the longest time, I decided to order my first ear mold combo. I was amazed by the lightness, sound quality, and the comfortable fit sitting naturally in my ear. I just love it, my next headset will be the same, and the next one as well. John-Thank you for your kind support and patience with all my questions, and the fast delivery to the other side of the world.

Z. Harach

Peach Aviation, KIX, Japan

The earpiece is awesome! The fit is very snug...FINALLY... after six years, I have an earpiece that keeps my headset in place. I was also very surprised at the noise reduction this earpiece (Satin Soft) provides. Thanks very much.

J. Vagim

Visalia, California

I've been using the custom earpieces with my Plantronics Headset for over one month, and would like to say what a wonderful product this is. No more uncomfortable headband, and the boombar/earpiece assembly is excellent; really comfortable. Thank you so much for a wonderful product and an excellent service; I have recommended and Avery Sound to my friends and colleagues.

C. Law

Belfast, Northern Ireland

The earpiece is very light and comfortable and provides an amazing reduction in comm box volume. No more bulky sets rubbing on the top of the head or that feeling of wearing an uncomfortable hat!! Many thanks once again for your service. I have recommended you to several colleagues already.

J. Robotham

Derby, United Kingdom