Development of a Customized CPAP Mask Using Reverse Engineering and Additive Manufacturing

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Ma, Zhichao
Munguia, Javier
Hyde, Philip
Drinnan, Michael

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University of Texas at Austin


Continuous positive airway pressure (CPAP) therapy has been widely used to treat moderate and/or severe Obstructive Sleep Apnoea (OSA) syndrome since its invention. However, CPAP mask interface induced side effects, such as air leak, noise, discomfort and facial skin problem, considerably affect the overall effectiveness of CPAP treatment. Conventional CPAP masks designed with averaged individual facial characteristics have standard configuration and limited material selection. Mask size ranges are limited, only coming with small, medium, and large. The material used for the mask interface fabrication is mainly silicone-based material. Besides the limitations on mask configuration and material, there are no comprehensive mask selection templates and guidance offered by CPAP mask suppliers. Individuals have completely different physical characteristics, such as face topology, skin sensitivity, the severity of OSA syndrome, sleep habit and breathing pattern. Therefore, conventional masks cannot properly fit individual’s physical characteristics. Customization of CPAP mask using Reverse Engineering and Additive Manufacturing techniques offers the great potential to minimize the CPAP mask interface induced side effects.


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