In truth @tenkan I have just recently had a new set of custom skeleton moulds made, from hard acrylic, this was a special fitting by Starkey UK Lab, much time & attention was taken on the impression, advice was sought from Starkey beforehand, the impression was marked, with various bits to be scalloped out (previous pain points) the results were impressive, for the first time ever in 30 odd years of trying to get a set of moulds that actually fitted perfect was actually achieved! There are no vents whatsoever…This was meant to to be a tester, to get the fit correct, so we could then order gold plated silicon moulds, at £200 a pop each, because of my allergies to silicon, I am fine with hard acrylic… It would appear, Starkey keeps a copy of your impressions indefinitely, they just need the serial number to reorder the exact same moulds! After trying these out for a couple of weeks, I am delighted to say, I have had no discomfort and no feedback, and they appear to be welded onto my lugs
it’s a slight effort to remove them! So, I have decided to forgo the gold plated version, and stick with these hard acrylic moulds… @Zeeza I don’t believe there is any specific size for double walled tubing as @Zebras states, the tubing is naturally soft and slightly elasticated, so it has a little movement, it takes a little practice to perfect retubing moulds, but after a few times it becomes much easier, double walled tubing will probably give you around another 5db of gain… Good Luck, cheers Kev 