Apple has been researching AirPod design for better fit, and a newly granted patent titled "Fabric-based earbuds" proposes a solution to personalize earbuds for every individual wearer. The patent describes using a three-dimensional sensor to capture precise ear images, analyzing dimensions such as tragus, antitragus, and concha. This data would then be used by 3D weaving equipment to create customized earbuds.

The patent details the specifics of weaving fabric in three dimensions, including weft strand, warp loops, and hooks, to form structures like AirPods. Beyond fit, Apple suggests fabric could offer desirable attributes such as sound permeability, light weight, and durability compared to plastic. The innovation aims to solve the challenge of obtaining precise measurements for millions of users, potentially making custom-fit AirPods a future reality.