Production of Custom Fit Oxygen Masks Using Rapid Prototyping Technology

Due to each individual's unique facial configuration, the four standard sizes of MBU-20/P oxygen masks, currently used by the USAF for up to 60 mm Hg positive pressure, do not fit everyone. This means that various individuals will require custom made oxygen masks. Foster-Miller, Inc., associated with the Gentex Corporation, the developer and current manufacturer of the MBU-20/P masks, will develop a detailed procedure to produce custom masks within two days. Phase I develops the procedure of anthropometric data collection of an individual's face compressed with a pressure that duplicates the action of the mask's seal on the face, when pressurized. This data will be digitized into a CAD file, which can be transmitted by modem. This digitized file will be used to make a reproduction of the seal area of a face using rapid prototyping technology, to prove the feasibility and accuracy of the method. Phase II develops the procedure to make a customized mold and the molding of a custom-made mask. The entire procedure uses techniques which are affordable, and the hardware and software developed can be used by semi-skilled personnel after a short period of training.