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Facial mask and method of making

  • US 10,463,823 B2
  • Filed: 06/10/2015
  • Issued: 11/05/2019
  • Est. Priority Date: 03/10/2014
  • Status: Active Grant
First Claim
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1. A method of manufacturing a facial mask, the method comprising:

  • obtaining a set of facial contours of a person'"'"'s face by one or more of digital photography, video, infrared, or laser scanning;

    optimizing a set of mask contours for an area where a mask will come in contact with the person'"'"'s face; and

    constructing a mask using an additive printing process including applying a first layer of a first material having first properties and applying a second layer of a second material having second properties and applying a first material gradient between the first and second layers in at least a portion of the mask, such that the first material is deposited in a first layer, and the second material is deposited in a second layer, with blends of the first and second materials deposited in intermediate layers, the intermediate layers providing the first material gradient, further wherein the first material gradient is characterized by the lack of a discernable boundary between the first and second materials and comprises a blend of the first and second materials;

    wherein the constructing step is performed such that the first material is a relatively softer material well suited to contact with the face of a patient, and the second material is a harder material well suited to providing a structure and shape to the mask;

    further wherein the blends of the first and second materials are formed prior to deposition according to mixing ratios, and the method comprises adjusting the mixing ratios as the intermediate layers are deposited;

    further wherein the constructing step comprises applying layers of material to form a mask having a first zone shaped to place over the bridge of the person'"'"'s nose, and a second zone shaped to place over the nostrils and/or mouth of the person, with a second material gradient therebetween, wherein the second material gradient provides a transition between the first zone and the second zone in which the first zone comprises a core skeleton element, the second zone omits the core skeleton element, and the second gradient transitions from inclusion of the core skeleton element at the first zone to absence of the core skeleton element in the second zone.

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