In a method for fabricating a hearing aid device, a patient visits an audiologist at a dispenser location, and is examined to determine electronic settings for a hearing aid to correct the patient's hearing impairment. At the same visit, an ear mold of the patient is obtained, which is scanned to produce a three-dimensional data set, from which a prototype is produced from the hearing aid data set, that does not contain any electronic components, and the prototype is test fitted with the patient. By interaction between the patient and the audiologist, the prototype is modified as needed. When the prototype is acknowledged by the patient as being a comfortable fit, the three-dimensional data that were used to create the acceptable prototype are electronically transmitted to a fabrication site, at which the hearing device is manufactured therefrom. The hearing device is then sent to a location at which it is available to the patient.