Hi,

You are looking at very tiny moulds and very fiddly small layups. 

I would suggest that traditional composites would unlikely be suitable for that purpose as the traditional methods such as wet lay, resin infusion and even pre-preg are more suited to bigger parts.

I'd imagine you would be better off looking down the casting resin or plastic injection type routes.  Many of the raw plastics are often "composites" as in use filler powders and strands etc to improve the performance but on a smaller scale.

As a DIY method, you could make a silicone mould then pour casting resin into it. Due to the size and scale, I would recommend vacuum degassing as a single small bubble could ruin things.  Plus you would need an "insert" you lowered into the centre portion of the mould so that it displaces resin where you want a void to give you the hollow section.

Even then at that size, it won't be an easy task to get right.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

I would say exactly the same as Warren...

This may help.

http://www.youtube.com/watch?v=jmsbUZPUvJY

You will then need to make a mould from this to cast your finished object.
If you use a silicon putty as in the video you may find that Silicon moulding material will stick to it.
Perhaps someone from easy composites can confirm this?
I am not sure if a hard resin will fit back in your ear comfortably. You may need something that flexes.

Brian.