A headgear or headgear segments are manufactured to shape thereby producing little or no waste material. Techniques such as knitting, braiding, crocheting, and 3D printing can be used produce the headgear.

A nasal assembly for delivering breathable gas to a patient includes a frame having an integrally formed first connector portion. A nozzle assembly includes a gusset or base portion and a pair of nozzles. At least one inlet conduit is structured to deliver breathable gas into the frame and nozzle assembly for breathing by the patient. A pair of second connector portions are removably and rotatably connected to respective first connector portions of the frame and are in communication with respective inlet conduits, e.g., directly or via angle connectors. A headgear assembly is removably connected to the pair of second connector portions and/or the angle connectors so as to maintain the frame and the nozzle assembly in a desired adjusted position on the patient's face.

A respiratory mask assembly for delivering breathable gas to a patient includes a frame having a front surface and a rear surface, opposite the front surface, and adapted in use to face the patient. The frame defines an inner wall and an outer wall extending from the rear surface, the inner and outer walls being spaced to define a channel therebetween. A cushion is removably attachable to the frame such that the cushion and frame are repeatably engagable with and disengagable from one another. The cushion includes a side wall to be inserted into the channel of the frame, the side wall having a first interlocking surface that engages a second interlocking surface provided in the channel when the cushion and frame are engaged with one another. The first and second interlocking surfaces interlock with one another to removably attach the cushion to the frame.

A respiratory assembly is provided. The assembly includes a base engaged with at least one connector and in fluid communication with a hose or fluid source for allowing the gaseous flowthrough between the at least one connector, the base and the hose or fluid source. The assembly further includes a pair of sockets engaged with the at least one connector, and a pair of posts, each post selectively engageable with at least one of the pair of sockets. Each post includes a flange that defines an opening therethrough, the openings in fluid communication with each corresponding socket of the pair of sockets. Each post further includes an adhesive adhered to each flange and configured for sealably engaging a patient's nare.

A customized mask is manufactured by the process of: generating surface geometry data of a face of a patient, the surface geometry data corresponding to and representing a surface geometry of the face of the patient; generating original cushion geometry data using the surface geometry data; generating modified cushion geometry data using the original cushion geometry data; producing a rigid support member using the modified cushion geometry data such that it is shaped according to the modified cushion geometry data, the support member being made of a unitary material; and coupling a sealing flap to the support member, the sealing flap being structured to engage the face of the patient.

Apparatus and methods automate selection of patient interface(s) according to their size, such as with processing in a processor(s) or in a server(s). Image data captured by an image sensor may be received. The captured image data may contain facial feature(s) of an intended user of the patient interface. The facial features may be captured in association with a predetermined reference feature of known dimension(s). The user's facial feature(s) and the reference feature may be detected in the captured image data. Image pixel data of the image may be processed to measure an aspect of the detected facial feature(s) based on the reference feature. A patient interface size may be detected from standard patient interface sizes based on a comparison between the measured aspect of the facial feature(s) and a data record relating sizing information of the standard patient interface sizes and the measured aspect of the facial feature(s).

A customizable mask including a conforming seal is configured to utilize the physical process of granular jamming to enable it to adapt to a wide range of facial geometries. The mask may include a frame having a perimeter and a conduit connection, a conforming seal positioned along the perimeter of the frame. The conforming seal may include a sealing surface and a connecting surface, the connecting surface configured to mate with the perimeter of the frame, and the sealing surface configured to conform to a users' face. The conforming seal may further include an outer casing, granular material contained within the outer casing, and a vacuum connection. The mask may also include a similarly configured conforming frame. Further disclosed are methods of forming such masks.

A method of manufacturing a patient interface for sealed delivery of a flow of air at a continuously positive pressure with respect to ambient air pressure to an entrance to the patient's airways includes collecting anthropometric data of a patient's face. Anticipated considerations are identified from the collected anthropometric data during use of the patient interface. The collected anthropometric data is processed to provide a transformed data set based on the anticipated considerations, the transformed data set corresponding to at least one customised patient interface component. At least one patient interface component is modeled based on the transformed data set.

A 3D data collection method with privacy protection includes obtaining a 3D scan of at least a portion of a patient, receiving an avatar template and control point registration data, identifying control points on the 3D scan based on the control point registration data, adjusting the avatar template to coincide control points on the avatar template with control points on the 3D scan, and transmitting the adjusted avatar template.

A respiratory mask assembly for delivering breathable gas to a patient includes a frame having a front surface and a rear surface, opposite the front surface, and adapted in use to face the patient. The frame defines an inner wall and an outer wall extending from the rear surface, the inner and outer walls being spaced to define a channel therebetween. A cushion is removably attachable to the frame such that the cushion and frame are repeatably engagable with and disengagable from one another. The cushion includes a side wall to be inserted into the channel of the frame, the side wall having a first interlocking surface that engages a second interlocking surface provided in the channel when the cushion and frame are engaged with one another. The first and second interlocking surfaces interlock with one another to removably attach the cushion to the frame.