frozensoda,

I would not trust any ABS filament to meet the quality standards that we had in the shop where I worked.  I think trying and designing ones for personal use is totally fine, but I wouldn't be comfortable selling them to others.  They should at a minimum only be used in fully healed lobes and not used to stretch nor directly after stretching.  Danny is correct to point out the porous surface area of these prints which will trap particles, oils and dead skin and scrap against the fistula. 

I think there is still tons of awesome designs and ideas that can be used in plug design, but having it pop into a steel tunnel or silicone skinlet would create a nice biocompatible layer between the print and the ear.

Thank you for this in-depth answer, I also arrived at the same conclusion. I have ordered 100 pairs of hollow silicon plugs to slip them into. I will tell my customers what to do, but of course I can not make them do it.

I would not trust any ABS filament to meet the quality standards that we had in the shop where I worked.  I think trying and designing ones for personal use is totally fine, but I wouldn't be comfortable selling them to others.  They should at a minimum only be used in fully healed lobes and not used to stretch nor directly after stretching.  Danny is correct to point out the porous surface area of these prints which will trap particles, oils and dead skin and scrap against the fistula. 

I think there is still tons of awesome designs and ideas that can be used in plug design, but having it pop into a steel tunnel or silicone skinlet would create a nice biocompatible layer between the print and the ear.

Took me a while to figure out the right sizes to make them stretch fit with a curved side instead of straight sides and keeping them in with a little 0-ring.

My favourite is the hexagonal curved tube one which is just 0.5mm thick. They're all printed in 0.3mm whilst I perfect the design.

You should not use these directly on human skin.  They should really be popped into an existing set a steel plugs.

she has rubber ones that they go in to

but why? is ABS an irritant?

I checked the MSDS and saw nothing to be concerned for... Is there some reason to think this would irritate skin?

(where pierced ear are stretched to large holes)

I also printed some of these when I first got my printer, but only 8mm ones with a star-shaped hole through them.

to be honest, I found that the size I printed (8mm) getting any kind of resolution on the print in the middle in such a little space was difficult/impossible, (these larger ones have come out good though).
and the layer height had to be 0.1mm else there were just too many "cavities" that looked like sweat and dead skin may build up in...

I have been modeling 1" plugs and printing them for my wife. Pictures below!

I have made 15 sets (30 pieces) so far and 12 pieces at once works perfectly I am going to sand them but I am also gonna test a set in the acetone vapor, to see which works better. I will be selling these at the flea market.