I am having a similar experience right now. The Friday before Christmas I had a programing session for my new Phonak Ambra aids. The Audiologist installed new slim tubes on a relatively new set of ear molds I had for my Exelias. I had not been able to wear those particular molds for more than 3 or 4 hours without irritation - but the soft molds for my Ambras were already showing wear, so I needed to give them a try.
I wore those molds for at lest 12 hours that day - and woke up with a terrible ache in my left ear Saturday morning. By the time I could see my nurse my ears were so blocked with wax she was unable to see into them. My primary care doctor prescribed peroxide drops to soften the wax, and cleaned my ears today. He found the outer canal of my left ear to be infected, and prescribed antibiotic drops and took a culture. I also have the stuffy feeling, I still feel blocked and have some pain.
My audiologist is sure the molds had nothing to do with the ear problem… I am not so sure…
I have a follow up appointment with ENT next week, for an ongoing Eustachian tube inflammation. I will bring this new issue up for sure.