Hand-built by skilled craftspeople, one pair at a time, for your ears alone. Every order includes a complimentary impression kit — it ships as soon as you order; the build runs 35–40 business days — the handwork that makes them last for years.
★★★★★ 4.0 · 56 verified Trustpilot reviewsPerfect-Fit Technology™Made in the USA
The cockpit never sounds dangerous — that’s the trap. A piston cabin holds a steady 85 to 95 decibels for the whole flight, spikes past 100 on run-up, and the FAA itself says protect your hearing once it passes 88 dB. It isn’t one loud moment — it’s every hour, every leg, over a career, until the ringing never leaves. Big Ear builds custom adapters that seal into the headset you already fly — or filtered plugs to wear beneath it — so the dose stays out while your radio, intercom and alerts stay perfectly clear.
Hearing damage starts at 85 dB. A piston cabin holds 85–95 dB every hour you fly — the 20 dB filter brings that under the damage threshold while ATC and intercom stay crisp.
★★★★★Verified on Trustpilot · we’re a 4.0 overall — read the bad ones too
I teach aerobatics in the Extra and Pitts. These airplanes are extremely loud. I had to change out my Clarity Aloft foams just about every day. My Big Ear Clarity Aloft adaptors have turned that around.
— An aerobatics instructor · Trustpilot
Hand-Built in the USACrafted by hand, one ear at a time
Medical-Grade SiliconePremium materials, built to endure
Warranty & RepairBacked for the long haul
Perfect-Fit GuaranteeSealed right — or we remake it
Custom Aviation Adapters & Earplugs
The best aviation upgrade isn’t a new headset — it’s a custom fit.
You trust a headset with every clearance, every leg, every hour aloft — and it shipped with a generic foam tip that aches, backs out and leaks sound right when the tower keys up. On long days that fatigue is real, and the cockpit’s ambient noise quietly chips at your hearing flight after flight.
Big Ear fixes both. A custom adapter, molded to your own ears, snaps onto the headset you already fly — Bose ProFlight, Clarity Aloft, CEP, UFQ, Halo — for a flawless seal, clearer comms and lower fatigue. Prefer standalone protection? Our custom aviation earplugs and filtered options guard your hearing in the cockpit and on the ramp. Hand-built in the USA, backed by a fit guarantee.
Real cockpit fit — the custom Bose ProFlight adapter, worn.
Real people, real care
Fit by hand, by people who get it.
We’re a family business, and we treat every pilot and rider like one of our own — meeting you at shows and rallies, fitting each ear by hand, and standing behind it for years. When your set is made for you, it’s because someone here made it, for you.
The Big Ear booth, on the road.
The noise reality
The cockpit is louder than you think — for hours
A general-aviation piston cockpit runs a sustained 85–95 dBA in cruise, with peaks past 100 dBA on run-up. The FAA itself recommends hearing protection once cockpit noise passes 88 dB. It isn’t one loud event — it’s the cumulative dose, flight after flight, across a flying career, that quietly costs pilots their hearing.
85–95 dBA
Piston cockpit, sustained in cruise
100+ dBA
Peaks during engine run-up
88 dB
FAA threshold to add protection
FAA Advisory Circular AC 20-133 recommends hearing protection above 88 dB in the cockpit. A custom-fit adapter for the headset you already own — or a filtered plug beneath it — seals that dose out while your radio, intercom and alerts stay perfectly clear.
Why Custom
Five Reasons Pilots Fly Custom
The tip in the box was built to ship cheap, not to fit your ear. Custom fixes every problem it creates — here’s why pilots and crews go custom.
01
Fits Your Headset
Custom adapters for every major in-ear headset — Bose ProFlight, Clarity Aloft, CEP, UFQ, Halo. Keep the gear you trust; lose the tip you hate.
02
Clearer Comms
A sound bore aimed straight at your eardrum sharpens every transmission, so you catch the clearance the first time.
03
All-Day Comfort
Molded to your ears, it seals once and disappears — no rolling, no re-seating, no pressure on the longest legs.
04
Real Protection
A true custom seal cuts cockpit and cabin noise, lowering fatigue and protecting the hearing your certificate depends on.
05
Built to Last
Handmade from medical-grade silicone, one set outlives years of disposable tips — and a future headset can often reuse your impressions.
Which One
Find Your Aviation Fit
The short version: if you fly with an in-ear headset, get the custom adapter — our Bose ProFlight Series 2 adapter is our #1 best-selling product. Want standalone protection? Choose custom or filtered earplugs. Here’s how they compare.
The custom adapter for the cockpit’s most popular in-ear headset — and our #1 best-selling product. A flawless seal and crystal-clear comms on the headset you already fly.
Standalone custom protection for the cockpit and ramp — a filtered, all-day seal molded to your ears, so the engine drops away and the radio stays clear.
A two-cent tip on a cockpit you trust your life to.
Your headset is the one link between you and every instruction that keeps the flight safe — and it ships with a tip designed to be cheap. Custom is the difference between hearing the clearance the first time and asking them to say again, and between fatigue at hour six and finishing the day sharp. Make the gear you already trust fit the ears you fly with.
Headset Adapters · Best Sellers
Aviation Headset Adapters
Our best-selling category. Whatever you fly behind — Bose ProFlight, Clarity Aloft, CEP, UFQ or Halo — we build a custom adapter that snaps onto your headset for a flawless seal and clearer comms. The Bose ProFlight Series 2 adapter is our #1 seller. Shop the best seller →
★ Best Seller$189.95
ADAPTER
Bose ProFlight Series 2 Custom Adapter
Our #1 best-selling product. A custom adapter that snaps onto the cockpit’s most popular in-ear headset for a flawless seal and crystal-clear comms.
The One® isn’t one filter — it’s a filter system with two positions, and you pick what goes in each. That’s what lets one custom plug be tuned to your ears and your world instead of a one-size compromise.
Position 1 · In the canal
Non-Linear Filter
Seats down in the canal and reacts to how loud the sound is. Quiet passes through so you keep your awareness — then the instant a sharp impulse hits, it clamps down, and opens right back up. This is the one you want when the danger arrives as a crack, a blast or a bang.
Position 2 · On the outside face
Flat-Attenuation Filter
Mounts on the outer face and turns the whole world down evenly, across every frequency — so the sound keeps its shape instead of going muddy the way foam makes it. This is the one you want for steady, sustained noise: wind, engines, a room, a mix.
Run one, or run both. Your dB level and filter choice are picked when you build your pair — and because they’re interchangeable, you can change your mind later without changing your earplugs. The Select and Premium levels simply give you more filters to swap between.
Accessories
Care & Accessories
Cups, pouches and lanyards to protect, carry and keep track of your custom adapters and earplugs.
$2.00
CUP
Big Ear Heavy Duty Earplug Cup
A rugged screw-top cup that keeps your custom plugs clean, paired and easy to find in a tank bag or jacket pocket.
Everything pilots, controllers and crews ask before going custom.
What is the best aviation headset upgrade?
For most pilots, the best upgrade is a custom adapter for the headset you already fly. It snaps onto your Bose ProFlight, Clarity Aloft, CEP, UFQ or Halo and replaces the generic tip with a molded seal — clearer comms, all-day comfort and real noise reduction. Our Bose ProFlight Series 2 adapter is our #1 best-selling product, and most adapters are $189.95.
Which headsets do you make adapters for?
We build custom adapters for the most popular in-ear aviation headsets — Bose ProFlight Series 1 and 2, Clarity Aloft, CEP, UFQ ANR L2/L1 and Quiet Technologies Halo — plus Apple AirPods Pro. Our best-seller is the Bose ProFlight Series 2 adapter.
Do I need adapters or earplugs?
If you fly with an in-ear headset, a custom adapter makes it fit and improves comms. If you want standalone protection for the cockpit, ramp or as a backup, custom or filtered aviation earplugs are molded for all-day comfort. Many pilots own both.
Do custom adapters improve safety?
Yes. A full seal and a sound bore aimed at your eardrum make transmissions clearer and let you run a lower volume, reducing fatigue and protecting your hearing — so you catch the clearance the first time, not the third.
How do I get ear impressions made?
Two easy ways: visit one of our 50+ providers for a quick ear impression, or order our mail-in Home Impression Kit and do it yourself. Send the impressions to our lab and we hand-craft your adapters or earplugs.
How much does it cost, and how long does it take?
Custom aviation earplugs start at $128.95, most headset adapters are $189.95, and filtered protection starts at $299.95. After we receive your impressions, hand-crafting typically takes about 35–40 business days, and we send tracking when your order ships.
Will the adapter still work if I upgrade my headset?
Often, yes. Because the adapter is molded to your ears, we can frequently rebuild or refit it for a new headset using your existing impressions — so your investment carries forward.
Is Big Ear used by professional pilots?
Yes. Our adapters and earplugs are used by airline and general-aviation pilots, air traffic controllers and military helicopter crews who depend on clear communication and lasting hearing.
What warranty comes with Big Ear aviation products?
Every product carries a fit warranty plus our repair program. If the fit isn’t right we make it right, and we repair your Big Ears to keep them serving you for years.
Ready To Gear Up?
How To Order
New to custom hearing protection? Tell us how you'll use it and we'll match you to the right product, get your ear impression handled, and walk you through every step.
