Systems and methods in accordance with embodiments of the invention fabricate objects using investment molding techniques. In one embodiment, a method of fabricating an object includes: fabricating a subassembly including a plurality of volumes; where each volume is defined by the homogenous presence or absence of a material; where fabricating the subassembly includes using an additive manufacturing process; where at least one of the plurality of volumes defines a shape that is to exist in the object to be fabricated; where at least a first of the plurality of volumes includes a first dissolvable material; dissolving the first dissolvable material; where the dissolution of the first dissolvable material does not dissolve at least one other material within the subassembly; forming at least one cavity within the subassembly; and introducing an additive material into the at least one cavity.

The present invention relates to a cushion element (14) for a patient interface (10) for providing a flow of breathable gas to a patient (12), wherein the cushion element (14) comprises a face-contacting layer (32) for contacting a face of the patient (12) during use of the cushion element (14); and a multi-layer responsive structure (34) which is covered by the face-contacting layer (32). The responsive structure (34) comprises a plurality of actuators (38, 40) for moving the face-contacting layer (32), wherein said plurality of actuators (38, 40) comprises first actuators (38) belonging to a first group of actuators and second actuators (40) belonging to a second group of actuators. Each of the first and the second actuators (38, 40) comprises an electrode (44, 46). The electrodes (44) of the first actuators (38) are arranged in one or more first layers (50), and wherein the electrodes (46) of the second actuators (40) are arranged in one or more second layers (52), wherein the one or more first and second layers (50, 52) are arranged above each other. The electrodes (44) of the first actuators (38) are, with respect to a first axis (42) transverse to the one or more first and second layers (50, 52), arranged spatially offset relative to the electrodes (46) of the second actuators (40) such that the electrodes (44) of the first actuators (38) do not overlap the electrodes (46) of the second actuators (40) when being viewed along the first axis (42).

A mask with cushion that has an outer film is disclosed. The film may be self-skinning or a film formed about or glued to the cushion body. In another form the cushion may be formed with at least a portion having a plurality of adjacent voids having honeycomb-like structure.

A system for determining an optimal hardness of a patient interface device includes a fit score determination unit structured to receive a 3-D model of the patient interface device and a 3-D model of a patient's face and to determine a fit score between the patient interface device and the patient's face based on the 3-D model of the patient interface device and the 3-D model of the patient's face, and a hardness determination unit structured to determine a hardness value of the patient interface device based on the determined fit score.

A pressure support system configured to deliver a pressurized flow of breathable gas to the airway of a subject is further configured to provide information to a user position, fit or seal between the subject and the patient interface through which the pressurized flow of breathable gas is delivered. Such information may include, for example, a location on the patient interface at which the integrity of the seal is compromised, adjustments that could be made by the subject to enhance the interface between the patient interface and the subject, different types and/or sizes of patient interfaces that could be used to enhance the fit and seal between the system and the subject, and/or other information.

Systems and methods permit generation of a digital scan of a user's face such as for obtaining of a patient respiratory mask, or component(s) thereof, based on the digital scan. The method may include: receiving video data comprising a plurality of video frames of the user's face taken from a plurality of angles relative to the user's face, generating a three-dimensional representation of a surface of the user's face based on the plurality of video frames, receiving scale estimation data associated with the received video data, the scale estimation data indicative of a relative size of the user's face, and scaling the digital three-dimensional representation of the user's face based on the scale estimation data. In some aspects, the scale estimation data may be derived from motion information collected by the same device that collects the scan of the user's face.

Conventional gas mask seals or gaskets are merely rubber flaps integral to and extending from the main body or shell of a gas mask that are conformed to the face of a wearer by tightening straps. The described gas masks comprise a separate gas mask seal and a gas mask shell. Some of the gas mask seals are individualized or customized to more tightly fit and conform to the face of the individual wearer and to provide greater comfort and protection. The gas mask seals may be made from three-dimensional image files developed directly from the wearer's facial features.

A non-invasive ventilation system may include an interface. The interface may include at least one gas delivery jet nozzle adapted to be positioned in free space and aligned to directly deliver ventilation gas into an entrance of a nose. The at least one gas delivery jet nozzle may be connected to a pressurized gas supply. The ventilation gas may entrain ambient air to elevate lung pressure, elevate lung volume, decrease the work of breathing or increase airway pressure, and wherein the ventilation gas is delivered in synchrony with phases of breathing. A support for the at least one gas delivery jet nozzle may be provided. A breath sensor may be in close proximity to the entrance of the nose. A patient may spontaneous breathe ambient air through the nose without being impeded by the interface.

A shroud (1020) for a mask system includes a retaining portion structured to retain a frame (1040), a pair of upper headgear connectors (1024) each including an elongated arm (1026) and a slot (1027) at the free end of the arm adapted to receive a headgear strap, and a pair of lower headgear connectors (1025) each adapted to attach to a headgear strap. The retaining portion, the upper headgear connectors, and the lower headgear connectors are integrally formed as a one piece structure.

A patient interface device includes a frame member and a cushion having a main body, a sealing portion, and first and second posts extending from the main body. The frame member defines a first orifice and a second orifice. The first post of the cushion is rotateably received within the first orifice and the second post is rotateably received within the second orifice in a manner that permits the cushion to rotate relative to the frame member.