I had some custom earplugs made, and had the same problem in the beginning. Bought them, put them in, and would get really sore inside my ear after 30 minutes or so of use.
I took them back, and told him to make the mold a bit shallower. A fraction of an inch was needed, and it has never been a problem since

I think that this video I made goes perfectly into this conversation. made a youtube video on how you can make your own custom earplug. It's well worth it!

YouTube - ‪how to: Mach 1 aviation headset custom earplug for 12 dollars‬‏

please thumbs up and rate my video! oh and comments/questions on the video in youtube would be fantastic... thanks!

Is this still up? If so, can you make it public so I can view it?

Go to any Hearing Aid store or and Audiologist.
I go mine custom made at hearing aid store, they fit just right no hot spots.:)

+1
I had my molds made by an audiologist specializing in hearing aids that I found on google. The molds were then sent to sensaphonics to make the plugs for my lightspeed mach 1. She was actually surprised that they wanted such a deep mold, to the second bend, maybe? For the first couple of months I was getting 'hot spots' and finding them uncomfortable until I figured out how to twist them while inserting to get the proper fit. Once I figured that out, had no discomfort wearing them for long, multi-leg RJ days. Same deal now flying long haul. There's no way I'd ever go back to wearing an over the head clamp. Not sure what I'll do when the lightspeed eventually gives out since they don't make it anymore.

Oh yeah, I think the charge for making the molds was ~$50.

My dentist made mine. Just like a bridge.

Sorry for the necropost. Anybody have a molded ear piece made for the Clarity Aloft Pro? Where did you have it done? If it’s an audiologist, how do they make it so it screws onto the CA? How is the noise reduction compared with the Comply eartips?