U.S. patent application number 14/524432 was filed with the patent office on 2015-02-12 for system and method for forming a custom medical mask from a three-dimensional electronic model.
This patent application is currently assigned to Airway Technologies, LLC. The applicant listed for this patent is W. Keith Thornton. Invention is credited to W. Keith Thornton.
Application Number | 20150045926 14/524432 |
Document ID | / |
Family ID | 38918071 |
Filed Date | 2015-02-12 |
United States Patent
Application |
20150045926 |
Kind Code |
A1 |
Thornton; W. Keith |
February 12, 2015 |
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.
Inventors: |
Thornton; W. Keith; (Dallas,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Thornton; W. Keith |
Dallas |
TX |
US |
|
|
Assignee: |
Airway Technologies, LLC
Carrollton
TX
|
Family ID: |
38918071 |
Appl. No.: |
14/524432 |
Filed: |
October 27, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11768457 |
Jun 26, 2007 |
8874251 |
|
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14524432 |
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60806657 |
Jul 6, 2006 |
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Current U.S.
Class: |
700/98 |
Current CPC
Class: |
A61M 16/0683 20130101;
A61M 2016/0661 20130101; B29C 64/386 20170801; G06F 30/00 20200101;
A61M 16/06 20130101 |
Class at
Publication: |
700/98 |
International
Class: |
G06F 17/50 20060101
G06F017/50; B29C 67/00 20060101 B29C067/00 |
Claims
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.
Description
RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C.
.sctn.119(e) of U.S. Provisional Application Ser. No. 60/806,657
filed Jul. 6, 2006.
TECHNICAL FIELD
[0002] This invention relates generally to masks for use in medical
and other clinical applications, and more particularly to a system
and method for forming a custom medical mask from a
three-dimensional electronic model.
BACKGROUND
[0003] Many people experience breathing problems on a recurring
basis, which often result in sleep disordered breathing (i.e.,
difficulty sleeping, snoring, or other more serious conditions such
as obstructive sleep apnea). As technology advances, people with
such breathing problems demand increased performance and comfort.
Previous devices for improving a user's breathing have included
face masks, nose masks, or nasal inserts that help deliver air to
the user's nose at positive pressure. These devices help force open
the user's breathing passage and thereby improve the user's
breathing. However, previous devices have often provided an
inadequate fit and thus have caused discomfort for users and failed
to adequately prevent leakage.
OVERVIEW
[0004] 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.
[0005] 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 at least 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.
[0006] According to another embodiment, a system for forming a
custom medical mask for a particular user from a three-dimensional
electronic model includes a photopolymer material, a
three-dimensional electronic model of a custom medical mask, and a
stereolithography apparatus. The three-dimensional electronic model
includes a first surface that corresponds to unique facial features
of the particular user. The stereolithography apparatus is operable
to focus a light source on the photopolymer material in a pattern
corresponding to the three-dimensional electronic model to
polymerize the photopolymer material to form the custom medical
mask for the particular user.
[0007] Certain embodiments may provide one or more technical
advantages. For example, certain embodiments may provide a custom
medical mask that conforms substantially optimally to a user's
unique facial features. Certain embodiments may provide improved
fit, increased comfort, reduced leakage, and improved performance,
whether for treating sleep disordered breathing, administering
anesthesia, or any other suitable purpose for which the custom
medical mask is used. In certain embodiments the process of
creating the three-dimensional electronic model does not apply any
force to the particular user's face that may affect the shape of
the model and the resulting custom medical mask. Certain
embodiments may allow for the more efficient fabrication of a
custom medical mask, which may include more efficient methods for
fabricating one or more fittings and or openings for a custom
medical mask. Certain embodiments may allow for data communication
over the Internet or other network such that acquiring data needed
to create the three-dimensional electronic model and fabricating
the custom medical mask from the three-dimensional electronic model
may be performed in different locations remote from one another.
Certain embodiments may provide all, some, or none of these
advantages. Certain embodiments may provide one or more other
technical advantages, one or more of which may be apparent to those
skilled in the art from the figures, descriptions, and claims
included herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] For a more complete understanding of the present invention
and certain of its advantages, reference is now made to the
following description, taken in conjunction with the accompanying
drawings, in which:
[0009] FIG. 1 illustrates an example method for forming a custom
medical mask;
[0010] FIG. 2 illustrates an example system for forming a custom
medical mask;
[0011] FIG. 3 illustrates an example module for use with an example
processing system;
[0012] FIGS. 4A to 4E illustrate example electronic models for use
in forming a custom medical mask;
[0013] FIG. 5 illustrates an example custom medical mask;
[0014] FIGS. 6A and 6B illustrate example electronic models for use
in forming a custom medical mask with an oral chamber;
[0015] FIG. 7 illustrates an example custom medical mask with an
oral chamber;
[0016] FIGS. 8A and 8B illustrate example electronic models for use
in forming a custom medical mask with a receptacle for a coupling
device;
[0017] FIG. 9 illustrates an example custom medical mask with a
receptacle for a coupling device;
[0018] FIG. 10 illustrates an example electronic model for use in
forming a custom medical mask with a fitting for a clinical gas
delivery system; and
[0019] FIG. 11 illustrates an example custom medical mask with a
fitting for a clinical gas delivery system.
DESCRIPTION OF EXAMPLE EMBODIMENTS
[0020] FIG. 1 illustrates an example method 10 for forming a custom
medical mask 18. In certain embodiments, steps of method 10 may
include data acquisition 12, data processing 14, and mask
fabrication 16 to form custom medical mask 18.
[0021] In certain embodiments, data acquisition 12 may represent a
process for collecting three-dimensional coordinate data
corresponding to unique facial features of a particular user. In
certain embodiments, data acquisition 12 may be performed using
surface digitization and/or three-dimensional measurement
techniques. For example, data acquisition 12 may utilize optical,
acoustical, and/or other scanning techniques, physical probing
techniques, and/or any other suitable techniques. In a particular
embodiment, data acquisition 12 may utilize one or more optical
scanners to acquire three-dimensional coordinate data corresponding
to certain features of a particular user's face. The
three-dimensional coordinate data collected through data
acquisition 12 may be formatted in any suitable manner. For
example, the three-dimensional coordinate data may be formatted as
a three-dimensional computer aided drafting (CAD) model. In a
particular embodiment, the three-dimensional coordinate data may be
stored as one or more point-cloud models.
[0022] In certain embodiments, data processing 14 may represent one
or more processes for electronically manipulating and/or modifying
the coordinate data collected in data acquisition 12. These
processes may include screening the coordinate data collected in
data acquisition 12, fitting the coordinate data collected in data
acquisition 12, converting the coordinate data collected in data
acquisition 12 from one format to another, and/or any of a number
of well-known data processing techniques known for use with
three-dimensional coordinate data. For example, screening the
coordinate data (also known as smoothing) may include
identification, modification, and/or removal of outlier coordinate
data points. As another example, fitting (also known as stitching)
may include aligning multiple sets of coordinate data collected in
data acquisition 12 such that the multiple sets may be used
together to form a single coordinate data set. As another example,
the coordinate data collected in data acquisition 12 may be
formatted as a point-cloud model and may be converted to a polygon
mesh model, Non-Uniform Rational B-Spline (NURBS) model,
stereolithography (STL) model, and/or any other appropriate
three-dimensional electronic model.
[0023] In certain embodiments, mask fabrication 16 may represent a
process for forming custom medical mask 18 as a physical embodiment
of a three-dimensional electronic model developed through data
acquisition 12 and data processing 14. In particular embodiments,
mask fabrication 16 may represent one or more well-known
rapid-prototyping techniques such as, for example,
three-dimensional printing (3DP), selective laser sintering (SLS),
and/or STL. One or more of these processes may be used to form
custom medical mask 18 as a physical embodiment of a
three-dimensional electronic model, such that custom medical mask
18 is configured to provide a custom fit to unique facial features
of a particular user.
[0024] FIG. 2 illustrates an example system 20 for forming a custom
medical mask 18 according to certain embodiments of method 10. In
the embodiment shown, system 20 includes scanning system 22,
processing system 26, and fabrication system 28. In particular
embodiments, scanning system 22 may be coupled to processing system
26 through one or more data connections 30, allowing for data
communication between scanning system 22 and processing system 26.
Similarly, in certain embodiments, processing system 26 may be
coupled to fabrication system 28 through the use of one or more
data connections 32, allowing for data communication between
processing system 26 and fabrication system 28. In certain
embodiments, as shown in FIG. 2, processing system 26 and
fabrication system 28 may be included in a combination system 24
that provides the functionality of both processing system 26 and
fabrication system 28. In alternative embodiments, scanning system
22 and processing system 26 may be included within a combination
system that provides the functionality of both scanning system 22
and processing system 26. In addition, in certain embodiments, the
functionality of one or more of scanning system 22, processing
system 26, and fabrication system 28 may each be distributed among
multiple components.
[0025] Each of scanning system 22, processing system 26, and
fabrication system 28 may include one or more processing modules.
FIG. 3 illustrates an example processing module 34 for use in
system 20. Processing module 34 may include one or more processing
units 36 coupled to one or more memory units 38 (which will be
referred to as "processing unit 36" and "memory unit 38" throughout
the remainder of this description). In certain embodiments,
operations performed by processing module 34 are collectively
performed by processing unit 36 and memory unit 38. Processing unit
36 may include any suitable microprocessor or microcontroller,
according to particular needs. Memory unit 38 may take the form of
volatile or nonvolatile memory including, without limitation,
magnetic media, optical media, random access memory (RAM),
read-only memory (ROM), removable media, or any other suitable data
storage component.
[0026] Referring back to FIG. 2, scanning system 22 represents a
system for collecting three-dimensional coordinate data for one or
more surfaces of a physical object. Scanner 22 may utilize one or
more of numerous well-known coordinate data collection techniques.
In certain embodiments, scanning system 22 represents an optical
scanner. In a particular embodiment, scanning system 22 represents
a hand-held three-dimensional optical scanner, such as a HANDYSCAN
3D available from AGILE MANUFACTURING INC. of Ontario, Canada.
[0027] Processing system 26 represents an electronic system for use
in performing one or more processes associated with data processing
14 on the three-dimensional coordinate data collected by scanning
system 22. In certain embodiments, processing system 26 may
represent a general purpose computer loaded with one or more
software applications on a computer-readable medium. In a
particular embodiment, these one or more software applications may
include GEOMAGIC STUDIO available from RAINDROP GEOMAGIC, INC. of
Research Triangle Park, N.C.
[0028] Fabrication system 28 represents a fully-automated or
partially-automated system for forming a physical object from a
three-dimensional electronic model. In certain embodiments,
fabrication system 28 may represent a 3DP system, an SLS system,
and/or an STL apparatus (SLA). In certain embodiments, an SLA
operates by "building" parts one layer at a time. In certain
embodiments, each layer may be formed by tracing a beam of light
across the surface of a photo-reactive liquid, such as a
photopolymer. In certain embodiments, the light may be focused on
the surface of the photopolymer using one or more lasers each
having a wavelength that is selected to interact with the
photopolymer to cause the selective polymerization of the
photopolymer wherever the laser is focused. In a particular
embodiment, fabrication system 28 may be a VIPER SLA system,
available from 3D SYSTEMS, INC. of Valencia, Calif. In a particular
embodiment, the material used in fabrication system 28 to form
custom medical mask 18 may include a photo-reactive epoxy resin,
such as the FOTOTEC SL resin available from DREVE OTOPLASTIK, GmbH
of Germany.
[0029] Data connections 30 and 32 each may represent one or more
data connections providing for data communication between scanning
system 22 and processing system 26 and between processing system 26
and fabrication system 28, respectively. Connections 30 and 32 may
include wireline, wireless, and/or optical connections. In certain
embodiments, one or more of connections 30 and 32 may represent a
network such as a local area network (LAN), metropolitan area
network (MAN), wide area network (WAN), global communications
network such as the Internet, or any other suitable network. In
certain embodiments, one or more of connections 30 and 32 may
include a single network and/or multiple networks of the same type
or different types to couple these components to one another,
according to particular needs.
[0030] FIGS. 4A through 4E illustrate example electronic models 40
for use in forming a custom medical mask 18. In certain
embodiments, one or more electronic models 40 may be stored in one
or more memory units 38 within one or more processing modules 34 of
system 20. FIG. 4A illustrates an example point-cloud model 40a
that includes a cloud of three-dimensional coordinate data.
Point-cloud model 40a represents an example of three-dimensional
coordinate data that may be collected through data acquisition 12
and/or through the use of one or more scanning systems 22. For
example, point-cloud model 40a may represent a collection of
individual coordinate data points corresponding with electronic
measurements of facial features of a particular user taken by one
or more scanning systems 22. In certain embodiments, point cloud
model 40a may represent multiple individual scans of a particular
user's face, with each scan fitted or stitched together with other
scans to form a single point-cloud model 40a. Point-cloud model 40a
may be stored as a text file, as a comma delimited file, as a tab
delimited file, and/or in any other appropriate electronic
format.
[0031] FIG. 4B illustrates an example polygon mesh model 40b that
includes a plurality of polygons interconnected to form a mesh. In
certain embodiments, polygon mesh model 40a may be formed from
point-cloud model 40a through a process of selectively connecting
adjacent pairs of coordinate data points from point-cloud model
40a. In certain embodiments, multiple polygons may be combined
and/or merged together to reduce the total number of polygons
included in polygon mesh model 40b. In the embodiment shown, each
polygon included within polygon mesh model 40b is represented as a
triangle. In alternative embodiments, any appropriate polygon or
polygons may be used to form polygon mesh model 40b. Polygon mesh
model 40b may be stored as a wire frame model, as a surface model,
and/or in any other appropriate electronic format.
[0032] FIG. 4C illustrates an example NURBS model 40c. In certain
embodiments, NURBS model 40c may represent one or more continuous
surfaces mathematically approximating numerous polygons from
polygon mesh model 40b. NURBS model 40c may be stored as an Initial
Graphics Exchange Specification (IGES) model, as a Standard for the
Exchange of Product Model Data (STEP) model, as an STL model,
and/or in any other appropriate electronic format.
[0033] FIG. 4D illustrates an example solid model 40d. Solid model
40d may represent an electronic model created by extruding and/or
offsetting one or more surfaces from NURBS model 40c and/or polygon
mesh model 40b. Solid model 40d may be stored as an IGES model, as
a STEP model, as an STL model, and/or in any other appropriate
electronic format.
[0034] FIG. 4E illustrates an example trimmed model 40e. Trimmed
model 40e may represent a trimmed version of solid model 40d with
one or more surfaces limited by one or more trim surfaces 42.
Trimmed model 40e may be stored as an IGES model, as a STEP model,
as an STL model, and/or in any other appropriate electronic
format.
[0035] In operation, according to particular embodiments, scanning
system 22 may collect coordinate data from the facial features of a
particular user. This coordinate data may be utilized to generate
point-cloud model 40a according to data acquisition 12. In certain
embodiments, point-cloud model 40a may be communicated via
connection 30 or otherwise to processing system 26. Processing
system 26 may perform one or more processing steps to manipulate
and/or modify the data collected by scanning system 22, according
to data processing 14. For example, the data collected by scanning
system 22 may be converted from point-cloud model 40a to one or
more of polygon mesh model 40b and NURBS model 40c. In certain
embodiments, one or more of polygon mesh model 40b and NURBS model
40c may be offset and/or extruded to form solid model 40d. The
thickness of the offset and/or extrusion may correspond to a
selected thickness for custom medical mask 18. For example, in
certain embodiments, the offset and/or extrusion thickness of solid
model 40d may be in the range between 0.05 and 0.20 inches. In a
particular embodiment, the offset and/or extrusion thickness of
solid model 40d may be 0.125 inches. In certain embodiments, the
offset and/or extrusion thickness of solid model 40d may vary and
may be different for different portions of solid model 40d.
[0036] In certain embodiments, solid model 40d may be trimmed to
selectively adjust and/or define a periphery of solid model 40d
using one or more trim surfaces 42 to create trimmed model 40e. In
certain embodiments, the one or more trim surfaces 42 may be
generated and/or utilized to define a periphery to correspond with
a selected shape for custom medical mask 18. For example, in a
particular embodiment, one or more trim surfaces 42 may be
generated and/or utilized to define a periphery around a region
corresponding to the particular user's mouth and portions of the
particular user's nose. In certain embodiments, the step of
trimming one or more surfaces to define a periphery may be
performed with one or more of point-cloud model 40a, polygon mesh
model 40b, NURBS model 40c, and/or solid model 40d. In certain
embodiments, trimmed model 40e may be communicated via connection
32 or otherwise to fabrication system 28. Fabrication system 28 may
perform one or more steps to form custom medical mask 18 from
trimmed model 40e.
[0037] FIG. 5 illustrates an example custom medical mask 18 that
may be formed, at least in part, by fabrication system 28. As
shown, custom medical mask 18 may include body 60, one or more
openings 62, and/or one or more tabs 64. Body 60 may represent one
or more pieces of thin material configured to cover the particular
user's nose and/or mouth. The one or more pieces of thin material
may be shaped to correspond to the unique facial features of the
particular user. The one or more pieces of thin material may
include a polymerized photopolymer material. The one or more
openings 62 may allow for access through body 60 to the particular
user's nostrils and/or mouth, when custom medical mask 18 is
positioned over the particular user's face. Tab 64 may operate to
couple custom medical mask 18 to one or more straps and/or other
devices to couple custom medical mask 18 to the particular user.
One or more of openings 62 and/or tabs 64 may be integrally formed
with body 60 when custom medical mask 18 is formed with fabrication
system 28. In these embodiments, electronic model 40 used with
fabrication system 28 to form custom medical mask 18 may include
model elements corresponding to the one or more openings 62 and/or
tabs 64. In alternative embodiments, one or more of openings 62
and/or tabs 64 may be added to body 60 after custom medical mask 18
is formed with fabrication system 28. For example, one or more
openings 62 may be cut, drilled, and/or pressed out of body 60
after body 60 has been formed. Similarly, one or more tabs 64 may
be coupled to body 60 through the use of an adhesive or any other
appropriate coupling technique.
[0038] In certain embodiments, the periphery of custom medical mask
18 may be defined by trim surface 42 in trimmed model 40e prior to
forming custom medical mask 18 with fabrication system 28. In
certain embodiments, the periphery of custom medical mask 18 may be
further modified and/or trimmed to achieve an improved fit and/or
desired shape for custom medical mask 18 after custom medical mask
18 is formed by fabrication system 28.
[0039] FIGS. 6A and 6B illustrate example electronic models 40 for
use in forming a custom medical mask 18 with an oral chamber. In
certain embodiments, it may be advantageous to form a custom
medical mask 18 having a chamber substantially surrounding the
mouth or lips of a particular user. Such a chamber may be
advantageous to allow the mouth and/or lips of the particular user
to move while the particular user is wearing custom medical mask
18. In certain embodiments, electronic model 40 for use in forming
custom medical mask 18 having an oral chamber may be generated
through the use of chamber model 44. Chamber model 44 may represent
an electronic surface and/or solid model corresponding to a
selected shape for an oral chamber for custom medical mask 18. In
certain embodiments, chamber model 44 may be combined, overlaid,
and/or merged with electronic model 40. In certain embodiments,
once chamber model 44 has been combined, overlaid, and/or merged
with electronic model 40, a trimmed model 40f may be developed such
that at least a portion of trimmed model 40f in region 46 does not
directly correspond to the facial features of the particular
user.
[0040] In an alternative embodiment, rather than using chamber
model 44 to generate trimmed model 40f, a physical mold or other
structure may be placed on the face of the particular user at the
time of data acquisition 12. In these embodiments, the
three-dimensional coordinate data collected for the particular
user's face may also include three-dimensional coordinate data of
the mold or structure. This three-dimensional coordinate data may
then be used to generate trimmed model 40f such that at least a
portion of trimmed model 40f in region 46 does not directly
correspond to the facial features of the particular user.
[0041] FIG. 7 illustrates an example custom medical mask 18, with
oral chamber 66, that may be formed, at least in part, by
fabrication system 28. As shown, in addition to the features
described above in relation to FIG. 5, custom medical mask 18 may
include oral chamber 66. Oral chamber 66 may represent a region of
body 60 corresponding with an area around the mouth or lips of the
particular user that is configured to be offset from the lips or
mouth of the particular user when custom medical mask 18 is
positioned on the particular user's face. In certain embodiments,
custom medical mask 18 may be formed with fabrication system 28
using trimmed model 40f. In certain embodiments, custom medical
mask 18 with oral chamber 66 may allow the particular user to move
their mouth and/or lips while custom medical mask 18 is positioned
on the particular user's face.
[0042] FIGS. 8A and 8B illustrate example electronic models 40 for
use in forming a custom medical mask 18 with a receptacle for a
coupling device. In certain embodiments, it may be advantageous to
form a custom medical mask 18 configured for use with a coupling
device 80. Coupling device 80 may represent one or more structures
configured to couple custom medical mask 18 to an oral appliance.
In a particular embodiment, coupling device 80 may represent a
sleeve with an opening 82 configured to receive a post and/or other
structure of an oral appliance. In particular embodiments, coupling
device 80 may further include one or more openings 84 configured to
receive a threaded set screw 86 to retain a post and/or other
structure of an oral appliance within coupling device 80. In
certain embodiments, an electronic model 40 for use in forming a
custom medical mask having a receptacle for a coupling device may
be generated through the use of receptacle model 48. Receptacle
model 48 may represent an electronic surface and/or solid model
corresponding to a selected shape for a receptacle for coupling
device 80. In a particular embodiment, receptacle model 48 may
represent an electronic surface and/or solid model shaped to
substantially surround the outer dimensions of coupling device 80.
In certain embodiments, receptacle model 48 may be combined,
overlaid, and/or merged with electronic model 40. In certain
embodiments, once receptacle model 48 has been combined, overlaid,
and/or merged with electronic model 40, a trimmed model 40g may be
developed for use in forming a custom medical mask 18 with a
receptacle for coupling device 80.
[0043] In an alternative embodiment, rather than using receptacle
model 44 to generate trimmed model 40g, a coupling device 80 may be
positioned on or near the face of the particular user at the time
of data acquisition 12. In these embodiments, the three-dimensional
coordinate data collected for the particular user's face may also
include three-dimensional coordinate data of coupling device 80.
This three-dimensional coordinate data may then be used to generate
trimmed model 40g such that trimmed model 40g includes a region
shaped to substantially surround the outer dimensions of coupling
device 80. Similarly, in certain embodiments, the three-dimensional
coordinate data collected for the particular user's face may also
include three-dimensional coordinate data of a portion of an oral
appliance. In embodiments in which the collected three-dimensional
coordinate data includes three-dimensional coordinate data of a
portion of an oral appliance, the data may be used to form a custom
medical mask that is custom oriented to the oral appliance based on
this collected data. In a particular embodiment, coupling device 80
may be precisely positioned relative to the teeth and unique facial
features of the particular user at the time of data acquisition 12,
such that custom medical mask 18 formed using the data collected in
data acquisition 12 may be custom oriented to the particular user's
teeth and unique facial features. For example, an oral appliance
with a post may be positioned within the particular user's mouth
and coupling device 80 may be coupled to a post of the oral
appliance positioned within the particular user's mouth at the time
of data acquisition 12. An oral appliance positioned within the
particular user's mouth may include a bite register, a wax mold, an
upper arch, and/or a lower arch.
[0044] FIG. 9 illustrates an example custom medical mask 18 with
receptacle 68 for a coupling device 80. Custom medical mask 18 with
receptacle 68 may be formed, at least in part, by fabrication
system 28. As shown, in addition to the features described above in
relation to FIGS. 5 and 7, custom medical mask 18 may include
receptacle 68 configured to receive coupling device 80. Receptacle
68 may represent a sleeve or enclosure in body 60 shaped to receive
and/or support coupling device 80. As shown, receptacle 68 may
include opening 70. Opening 70 may be configured to allow access
through body 60 for another structure, such as a post of an oral
appliance. One or more of receptacle 68 and/or opening 70 may be
integrally formed with body 60 when custom medical mask 18 is
formed with fabrication system 28. In these embodiments, electronic
model 40 used with fabrication system 28 to form custom medical
mask 18 may include model elements corresponding to the one or more
of receptacle 68 and/or opening 70. For example, custom medical
mask 18 may be formed with fabrication system 28 using trimmed
model 40g. In alternative embodiments, one or more of receptacle 68
and/or opening 70 may be added to body 60 after custom medical mask
18 is formed with fabrication system 28. For example, opening 70
may be cut, drilled, and/or pressed out of body 60 after body 60
has been formed. In certain embodiments, custom medical mask 18
with receptacle 68 may cooperate with coupling device 80 to couple
custom medical device 18 to an oral appliance to improve the
positioning and/or fit of custom medical mask 18 for the particular
user.
[0045] FIG. 10 illustrates an example electronic model for use in
forming a custom medical mask 18 with a fitting for a clinical gas
delivery system. In certain embodiments, it may be advantageous for
custom medical mask 18 to couple to a suitable clinical gas
delivery system. A suitable clinical gas delivery system may be a
Continuous Positive Airway Pressure (CPAP) system, a Bilevel
Positive Airway Pressure (BiPAP) system, and/or a system configured
to deliver an anesthetic, oxygen, and/or other appropriate clinical
gases to a particular user wearing custom medical mask 18. In
certain embodiments, an electronic model 40 for use in forming a
custom medical mask having a fitting for a clinical gas delivery
system may be generated through the use of fitting model 50. In
certain embodiments, fitting model 50 may be combined, overlaid,
and/or merged with electronic model 40 to generate trimmed model
40h. Fitting model 50 may represent an electronic replica of a
fitting configured to couple custom medical mask 18 to a clinical
gas delivery system. In certain embodiments, once fitting model 50
has been combined, overlaid, and/or merged with electronic model
40, a trimmed model 40h may be developed for use in forming a
custom medical mask 18 with a fitting for a clinical gas delivery
system.
[0046] FIG. 11 illustrates an example custom medical mask 18 with
fitting 72 for a clinical gas delivery system. Custom medical mask
18 with fitting 72 may be formed, at least in part, by fabrication
system 28. As shown, in addition to the features described above in
relation to FIGS. 5, 7, and 9, custom medical mask 18 may include
fitting 72 configured to couple to a clinical gas delivery system
such as a CPAP system or a BiPAP system. Fitting 72 may represent a
structure configured to deliver a flow of gas from one or more
hoses and/or tubes through an opening in body 60. In a particular
embodiment, fitting 72 may represent a tube positioned to deliver a
flow of gas to one or more nostrils of the particular user when the
custom medical mask is positioned on the particular user's face.
Fitting 72 may be integrally formed with body 60 when custom
medical mask 18 is formed with fabrication system 28. In these
embodiments, electronic model 40 used with fabrication system 28 to
form custom medical mask 18 may include model elements
corresponding to fitting 72. For example, custom medical mask 18
may be formed with fabrication system 28 using trimmed model 40h.
In alternative embodiments, fitting 72 may be added to body 60
after custom medical mask 18 is formed with fabrication system 28.
For example, fitting 72 may be coupled to body 60 through the use
of an adhesive or any other appropriate coupling technique. In
certain embodiments, custom medical mask 18 with fitting 72 may
cooperate with a clinical gas delivery system to deliver a clinical
gas, such as anesthetic, oxygen, and/or air, to the particular user
when the custom medical mask is positioned on the particular user's
face.
[0047] Although the present invention has been described in several
embodiments, a plenitude of changes, substitutions, variations,
transformations, and modifications may be suggested to one skilled
in the art, and it is intended that the present invention encompass
such changes, substitutions, variations, transformations, and
modifications as fall within the scope of the appended claims.
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