An improved method of designing hearing aid molds is disclosed whereby regions of an ear impression model are identified as a function of a geodesic distance measure. According to a first embodiment, a canal point of an ear impression model is identified as that point having a maximum normalized geodesic distance as compared to all other points on the surface of the ear impression model. According to a second embodiment, a helix point of the ear impression model is identified as that point having a maximum normalized geodesic distance as compared to all points except those points in the canal region of said ear impression model. Finally, in accordance with another embodiment, a geodesic distance between a canal point and a helix point of an ear impression model is identified and a percentage threshold, illustratively 65%, is applied to that geodesic distance to identify a crus region.