System and method for forming a custom medical mask from a three-dimensional electronic model

Abstract

According to one embodiment, a custom medical mask formed for a particular user from a three-dimensional electronic model includes a body formed from a polymerized photopolymer material. An interior surface of the body is configured to seat on the particular user's face and comprises a physical embodiment of a three-dimensional electronic model corresponding to unique facial features of the particular user. According to another embodiment, a method of creating a three-dimensional electronic model for use in forming a custom medical mask for a particular user includes scanning a portion of the particular user's face using an electronic scanning device, generating a three-dimensional electronic model of the portion of the particular user's face based on the scanning, and transmitting the three-dimensional electronic model of the portion of the particular user's face for use in forming the custom medical mask for the particular user from a photopolymer using a stereolithography apparatus.

1 - 20 . (canceled) 
     
     
         21 . A method for use in forming a custom medical mask for a particular user, the method comprising:
 scanning at least a portion of a particular user's face using an electronic scanning device;   generating a three-dimensional electronic model of the portion of the particular user's face based on the scanning;   processing the three-dimensional electronic model to form an electronic model of a custom medical mask, the processing comprising:
 merging the three-dimensional electronic model with an electronic fitting model representing a fitting shaped to couple to a clinical gas delivery system; and 
 merging the three-dimensional electronic model with an electronic model selected from the group consisting of:
 a model of an oral chamber shaped to be offset from the mouth of the particular user when the custom medical mask is positioned on the particular user's face; and 
 a model of a coupling device shaped to couple the custom medical mask to an oral appliance; and 
 
   transmitting the electronic model of the custom medical mask for use in forming a custom medical mask for the particular user with a rapid prototyping technique.   
     
     
         22 . The method of  claim 21 , wherein the three-dimensional electronic model further comprises extruding a surface of the three-dimensional electronic model in a direction normal to the surface a distance between 0.05 and 0.20 inches. 
     
     
         23 . The method of  claim 21 , wherein the rapid prototyping technique includes a technique selected from the group consisting of three-dimensional printing, selective laser sintering, and stereolithography. 
     
     
         24 . A method for use in forming a custom medical mask for a particular user, the method comprising:
 scanning at least a portion of a particular user's face using an electronic scanning device;   generating a three-dimensional electronic model of the portion of the particular user's face based on the scanning;   processing the three-dimensional electronic model to form an electronic model of a custom medical mask, the processing comprising:
 merging the three-dimensional electronic model with an electronic fitting model representing a fitting shaped to couple to a clinical gas delivery system; and 
 merging the three-dimensional electronic model with an electronic model of an oral chamber shaped to be offset from the mouth of the particular user when the custom medical mask is positioned on the particular user's face; and 
   transmitting the electronic model of the custom medical mask for use in forming a custom medical mask for the particular user with a rapid prototyping technique.   
     
     
         25 . A method for use in forming a custom medical mask for a particular user, the method comprising:
 scanning at least a portion of a particular user's face using an electronic scanning device;   generating a three-dimensional electronic model of the portion of the particular user's face based on the scanning;   processing the three-dimensional electronic model to form an electronic model of a custom medical mask, the processing comprising:
 merging the three-dimensional electronic model with an electronic fitting model representing a fitting shaped to couple to a clinical gas delivery system; and 
 merging the three-dimensional electronic model with an electronic model of a coupling device shaped to couple the custom medical mask to an oral appliance; and 
   transmitting the electronic model of the custom medical mask for use in forming a custom medical mask for the particular user with a rapid prototyping technique.   
     
     
         26 . A custom medical mask formed for a particular user from a three-dimensional electronic model, comprising:
 a body having an interior surface and an exterior surface, wherein the interior surface of the body is configured to seat on the particular user's face and comprises a physical embodiment of a three-dimensional electronic model corresponding to unique facial features of the particular user;   a fitting configured to couple to a clinical gas delivery system, wherein the fitting and the body form one integral piece of material; and   at least one selected from the group consisting of:
 an oral chamber shaped to be offset from the mouth of the particular user when the custom medical mask is positioned on the particular user's face; and 
 a coupling device shaped to couple the custom medical mask to an oral appliance; 
   wherein the three-dimensional electronic model was merged with an electronic fitting model and at least one of a model of an oral chamber and a model of a coupling device.   
     
     
         27 . The custom medical mask of  claim 26 , wherein the exterior surface of the body is offset from the interior surface a distance between 0.05 and 0.20 inches. 
     
     
         28 . A custom medical mask formed for a particular user from a three-dimensional electronic model, comprising:
 a body having an interior surface and an exterior surface, wherein the interior surface of the body is configured to seat on the particular user's face and comprises a physical embodiment of a three-dimensional electronic model corresponding to unique facial features of the particular user;   a fitting configured to couple to a clinical gas delivery system, wherein the fitting and the body form one integral piece of material; and   an oral chamber shaped to be offset from the mouth of the particular user when the custom medical mask is positioned on the particular user's face; and   wherein the three-dimensional electronic model was merged with an electronic fitting model and a model of an oral chamber.   
     
     
         29 . A custom medical mask formed for a particular user from a three-dimensional electronic model, comprising:
 a body having an interior surface and an exterior surface, wherein the interior surface of the body is configured to seat on the particular user's face and comprises a physical embodiment of a three-dimensional electronic model corresponding to unique facial features of the particular user;   a fitting configured to couple to a clinical gas delivery system, wherein the fitting and the body form one integral piece of material; and   a coupling device shaped to couple the custom medical mask to an oral appliance;   wherein the three-dimensional electronic model was merged with an electronic fitting model and a model of a coupling device.   
     
     
         30 . A computer-implemented system for use in connection with forming a custom medical mask for a particular user from a three-dimensional electronic model, comprising:
 one or more memory units storing a three-dimensional electronic model of a custom medical mask, the three-dimensional electronic model suited for use with a rapid prototyping system; and   one or more processing units coupled to the one or more memory units and operable to access the three-dimensional electronic model in the one or more memory units for use in connection with forming a custom medical mask for a particular user using the rapid prototyping system;   wherein the three-dimensional electronic model of the custom medical mask comprises:   a first surface that corresponds to unique facial features of the particular user;   a model of a fitting configured to couple to a clinical gas delivery system;   a model selected from the group consisting of:
 a model of an oral chamber shaped to be offset from the mouth of the particular user when the custom medical mask is positioned on the particular user's face; and 
 a model of a coupling device shaped to couple the custom medical mask to an oral appliance; 
   wherein the model of the fitting and the selected model have been merged with the first surface.   
     
     
         31 . The system of  claim 30 , wherein the three-dimensional electronic model further comprises a second surface offset from the first surface a distance between 0.05 and 0.20 inches. 
     
     
         32 . The system of  claim 30 , wherein the one or more processing units are operable to access the three-dimensional electronic model over a network. 
     
     
         33 . A computer-implemented system for use in connection with forming a custom medical mask for a particular user from a three-dimensional electronic model, comprising:
 one or more memory units storing a three-dimensional electronic model of a custom medical mask, the three-dimensional electronic model suited for use with a rapid prototyping system; and   one or more processing units coupled to the one or more memory units and operable to access the three-dimensional electronic model in the one or more memory units for use in connection with forming a custom medical mask for a particular user using the rapid prototyping system;   wherein the three-dimensional electronic model of the custom medical mask comprises:   a first surface that corresponds to unique facial features of the particular user;   a model of a fitting configured to couple to a clinical gas delivery system; and   a model of an oral chamber shaped to be offset from the mouth of the particular user when the custom medical mask is positioned on the particular user's face; and   wherein the model of the fitting and the model of the oral chamber have been merged with the first surface.   
     
     
         34 . A computer-implemented system for use in connection with forming a custom medical mask for a particular user from a three-dimensional electronic model, comprising:
 one or more memory units storing a three-dimensional electronic model of a custom medical mask, the three-dimensional electronic model suited for use with a rapid prototyping system; and   one or more processing units coupled to the one or more memory units and operable to access the three-dimensional electronic model in the one or more memory units for use in connection with forming a custom medical mask for a particular user using the rapid prototyping system;   wherein the three-dimensional electronic model of the custom medical mask comprises:   a first surface that corresponds to unique facial features of the particular user;   a model of a fitting configured to couple to a clinical gas delivery system; and   a model of a coupling device shaped to couple the custom medical mask to an oral appliance;   wherein the model of the fitting and the model of the coupling device have been merged with the first surface.