Developing Custom-Fit CPAP Mask Prototype in Patients With Obstructive Sleep Apnea

Area of Science:

• Biomedical Engineering
• Medical Device Development
• Sleep Medicine

Background:

• Obstructive sleep apnea (OSA) is prevalent and associated with significant cardiovascular risks.
• Continuous positive airway pressure (CPAP) is the gold standard treatment for OSA.
• Poor mask fit, often due to limited sizing, is a major barrier to CPAP therapy adherence.

Purpose of the Study:

• To investigate the feasibility of creating custom-fit CPAP masks using accessible 3D technologies.
• To develop a prototype for personalized CPAP masks addressing fit and comfort issues.
• To assess the potential for in-office fabrication of custom CPAP masks.

Main Methods:

• Utilized 3D facial scanning (Structure Sensor) and computer-aided design (Autodesk Fusion 360) for personalized mask design.
• Fabricated prototypes using masked stereolithography (MSLA) 3D printing with standard resin.
• Incorporated medical-grade foam lining for enhanced comfort and safety evaluations (flow rate, pressure drop, CO2 rebreathing).

Main Results:

• Successfully developed a custom-fit CPAP mask prototype.
• Estimated production cost per mask is approximately $25.
• Prototype met key safety evaluation criteria for airflow and CO2 levels.

Conclusions:

• Affordable 3D scanning, CAD, and printing enable in-office fabrication of custom CPAP masks.
• This approach shows potential for improving patient comfort, mask fit, and CPAP adherence.
• Further biocompatibility testing and user feedback are necessary for clinical implementation.