A system and method to match an interface to the face of a user for respiratory therapy. A facial image of the user is stored. Facial features based on the facial image are determined. A database stores facial profiles based on facial features and a corresponding plurality of interfaces. A database stores operational data of respiratory therapy devices with the plurality of corresponding interfaces. A selection engine is coupled to the databases. The selection engine is operative to select an interface for the user from the plurality of corresponding interfaces based on a desired outcome based on the stored operational data and the facial features. The collected data may also be employed to determine whether the selected interface is correctly fitted to the face of the user.

An interface includes a mask. The mask includes a frame and a seal supported by the frame. Headgear is connected to the mask. The interface includes at least one of (i) an adjustment mechanism that can be set to a use length for a loop defined by the mask and the headgear; and (2) a break-fit assembly that can selectively lengthen the loop defined by the mask and the headgear and return to the use length.

Masks for various uses and methods for manufacture thereof, including masks for use in continuous positive air pressure (CPAP) therapies. An example includes a mask having a first, relatively softer material for contact with the face of the user, and a second, relatively harder or more structural material used away from the face of the user, with a gradient therebetween. The mask can be produced by additive manufacturing to avoid a discernible boundary between the first and second materials. The mask may include a foam element, which can be removable for replacement in some examples, for contacting the patient's skin.

A nasal interface device configured to be positioned about a user's nose includes an air supply interface body including an air supply opening, at least one nasal opening, and first and second side slots and first and second elastic members extending through the first and second side slots, respectively, on the air supply interface body. Each of the first and second elastic members includes first and second adhesive means on an outer end thereof distal from the air supply interface body. The nasal interface device includes a bendable metallic member including a bridge portion between first and second ends, wherein the first and second elastic members attach to the first and second ends of the bendable metallic member, respectively.

A respirator mask liner is provided for positioning between a respirator mask and the face of a wearer. The mask liner includes a flexible sheet material having an outer perimeter edge portion and a hole that is spaced inwardly from the outer perimeter edge portion. At least one tab projects outwardly from portions of the perimeter edge portion, and may be unitarily formed with the sheet material. The mask liner is configured so that when it is to be placed between the face of the wearer and the respirator mask, the tab or tabs project outwardly beyond the gasket portion of the respirator mask, so that the tabs may be used for adjusting the liner or securing the liner to the mask. Optionally, the mask liner has a surface texture with a ribbed and undulating pattern of raised portions, and/or incorporates an anti-microbial substance.

A breathing mask for use in administering inhalable medications to a patient in need of an inhaled drug is provided. The mask disclosed herein is particularly useful for use with very young children. The mask is made from a flexible molded plastic silicone or elastomeric material, and has an anthropometrically/anatomically/ergonomically contoured shape to provide a good seal, a comfortable fit, and minimal dead space within the mask. The airway is aligned with nose. There may be an orifice for use with a soother device to calm a child using the mask. Also provided is a visual flow indicator to provide an indication of the quality of the seal of the mask on the face.

An electronic apparatus includes a compilation unit structured to receive a plurality of different 3-D models of a patient's face, to compare the different 3-D models of the patient's face and to determine additional information about the patient's face based on the comparison, wherein the additional information includes at least one of a location of hard tissue, a depth of soft tissue, and a compliance of soft tissue, and wherein the patient's face is manipulated between the different 3-D models.

A face mask for extended wear by a user including a customized, contoured facial mask portion constructed and configured to cover and matingly contact a corresponding contoured surface area of a human face, preferably formed by 3D printing methods and materials. The face mask includes strap attachments and at least one strap for securing the customized, contoured facial mask portion to the face.

A method of generating a customized headgear that includes a plurality of physical features and being usable with a mask component that supplies a flow of breathing gas to the patient's airways. The method includes receiving one or more parameters pertaining to the patient's head, subjecting at least some of the parameters to one or more algorithms to determine at least one of a length of a physical feature of the plurality of physical features and an angle between a pair of physical features of the plurality of physical features, generating an outline of at least a portion of a body which, when formed, is usable to assemble therefrom at least a portion of the headgear, and outputting a pattern usable to enable the formation of the at least portion of the body from at least a first sheet of at least a first material.

A respiratory interface device is provided that includes a cushion and a faceplate. The cushion is structured to be coupled to the faceplate. The faceplate includes a peripheral end and a number of custom features. The cushion is coupled to the faceplate adjacent the faceplate peripheral end.