Objective To investigate the solutions to the comfort problem caused by traditional batch produc‐tion that cannot satisfy everyone's request .Methods The both objective and subjective evaluations were put forward to the assessment of ear comfort .The accurate data about the pinna was acquired through reverse engineering and extracting key points of the pinna by image detection method .The headphone model was built by the semi-parame‐ter design .Through the FESA study ,headphones - pinna contact pressure was assessed and relevant parameters were improved .Comfort was analyzed by contact pressure .Results The simulation contact pressure was compared before and after optimizing parameters .The results showed that the contact area of the augment cymba conchae could obtain more uniformity pressure .Conclusion The example verification shows this delivers better comfort than traditional one .The research has some reference value for the design and option comfortable headphones .