Non-invasive ventilation is the delivery of breathing support via a face mask. It is used to treat individuals whose breathing is compromised. Evidence shows that when used long term it improves both quality of life and life expectancy.

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Mass produced masks are available, but in children it is often difficult to find a mask that fits correctly and provides an adequate seal to deliver the therapy efficiently. Leaks around the edges of the mask can cause discomfort and reduce effectiveness. Often, parents and carers will tighten the mask straps to close gaps between the face and the mask, leading to further discomfort, skin breakdown and, especially in growing faces, asymmetric tissue development. This is especially true if the patient has existing abnormal facial geometry due to an underlying condition.

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This research explored the application of face scanning and additive manufacturing technologies to enable the delivery of customised face masks for children and infants. Participatory research methods involving children and parents have helped specify technology, techniques, materials and process that can be used, within the NHS, to deliver novel mask-face interfaces in a way that suits the needs of individual patients.

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Delivered in collaboration with Sheffield Children's Hospital NHS Foundation Trust and funded by NHRI i4i programme the study resolved designs that met customisation and biocompatibility  requirements, currently subject to disclosure (IPR) embargo.

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Contact Heath if you'd like to further information.