A dimensionally accurate clear model of the human scala tympani has be
en produced to evaluate the insertion and position of clinically appli
ed intracochlear electrodes for electrical stimulation. Replicates of
the human scala tympani were made from low melting point metal alloy (
LMA) and from polymethylmeth-acrylate (PMMA) resin. The LMA metal cast
s were embedded in blocks of epoxy and in clear silicone rubber. After
removal of the metal alloy, a cavity was produced that accurately mod
els the human scala tympani. Investment casting molds were made from t
he PMMA scala tympani casts to enable production of multiple LMA casts
from which identical models were fabricated. Total dimensional distor
tion of the LMA casting process was less than 1% in length and 2% in d
iameter. The models have been successfully integrated into the design
process for the iterative development of advanced intracochlear electr
ode arrays at UCSF. These fabrication techniques are applicable to a w
ide range of biomedical design problems that require modelling of visu
ally obscured cavities.