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Workflow to develop 3D designed personalized neonatal CPAP masks using iPhone structured light facial scanning
Amika A Kamath1, Marielle J Kamath1, Selin Ekici1
1Departments of Radiology, Mayo Clinic Axil School of Medicine, 200 First St., Rochester, MN, 55905, USA.
3D Printing in Medicine
|August 1, 2022
Summary
Custom-fit nasal CPAP (nCPAP) masks, created using 3D scanning, significantly reduce skin pressure and strap tension in neonates. This innovation aims to improve nCPAP therapy efficacy and minimize complications for preterm infants.
Area of Science:
- Biomedical Engineering
- Neonatology
- Medical Device Design
Background:
- Nasal continuous positive airway pressure (nCPAP) is crucial for respiratory support in neonatal intensive care units.
- Current nCPAP masks have limited sizes, leading to poor fit, skin pressure, and adverse outcomes in preterm infants.
- Custom-fit nCPAP masks are hypothesized to improve fit, reduce pressure, and enhance therapy efficacy.
Purpose of the Study:
- To evaluate methods for creating 3D neonatal facial models for custom nCPAP masks.
- To assess the effectiveness of 3D-printed custom nCPAP mask inserts in reducing pressure and tension.
- To determine the feasibility of using accessible 3D scanning technology for individualized nCPAP mask development.
Main Methods:
- Structured light scanning (using iPhone X with Bellus3D FaceApp or Heges) was employed to generate accurate 3D neonatal facial models.
- Computer-aided design (CAD) was used to create custom nCPAP mask inserts.
- 3D printed molds and silicon injection were utilized for manufacturing the individualized inserts.
- Pressure and strap tension sensors measured the effectiveness of the custom inserts on model neonatal faces.
Main Results:
- Structured light scanning provided accurate 3D facial models, unlike photogrammetry and laser scanning.
- Customized nCPAP mask inserts effectively reduced both surface skin pressure and mask strap tension.
- Pressure reductions exceeded 50% in some cases compared to standard nCPAP masks without inserts.
Conclusions:
- Accessible structured light scanning devices offer a low-cost, safe, and accurate method for capturing neonatal facial topography.
- 3D-scanned and manufactured nCPAP mask inserts significantly decrease skin and strap pressure at therapeutic CPAP levels.
- This workflow presents a viable approach for producing individualized nCPAP masks to mitigate complications arising from poor fit in neonates.
