0624 Novel Automatic Software-Generated Custom CPAP Mask to Optimize Patient Fit: Finite Element Analysis Results

Abstract Introduction Poor adherence to CPAP therapy remains a critical challenge in managing Obstructive Sleep Apnea (OSA), often driven by discomfort and poor fit from standardized masks. Mask leaks and pressure points are primary patient complaints. We hypothesized that a fully customized, patient-specific CPAP mask would significantly improve comfort by optimizing fit and pressure distribution. To achieve this, we developed a novel, automated software pipeline to translate 3D facial scans directly into 3D-printable mask designs. Methods We developed a software application to import 3D facial scans. The software automatically processes the scan and generates a patient-specific mask interface (CAD file) for 3D printing in a medical-grade flexible polymer. To validate this workflow, we acquired a facial scan then performed a Finite Element Analysis (FEA). The facial scan was modeled as epoxy resin commonly used to simulate soft tissue and the mask was assigned its polymer properties. We simulated a total headgear force of 5N (Newtons) to predict the resulting contact pressure and its distribution. Results The software successfully processed the facial scan automatically with a full face design. The FEA simulated a 5N headgear force. The custom masks produced a mean peak contact pressure of 27 kPa. As predicted, pressure was mostly evenly distributed across the seal, with minor, localized increases near the strap anchor points. In contrast, current literature reports a 5N headgear force with a standard mask was found to have peak contact forces of 69kPA with concentrated peak pressures on the zygoma. Conclusion An automated software workflow to create patient-specific CPAP masks is a rapid and feasible process. Finite Element Analysis predicts that these custom designs distribute headgear forces more evenly and create lower peak pressure points, especially on the zygoma, compared to standard masks. This suggests a biomechanical mechanism for improved patient comfort. Clinical studies are warranted to confirm this simulation in an OSA population and if this reduction in contact pressure translates to improved CPAP adherence. Support (if any) None.