Method for evaluating the fit of custom-fit Continuous Positive Airway Pressure masks using finite element analysis

Erica Martelly, Sandeep Rana and Kenji Shimada

Computer Methods in Biomechanics and Biomedical Engineering, 2025, vol. 28, issue 11, 1800-1817

Abstract: Continuous Positive Airway Pressure (CPAP) is a common therapy used to treat breathing disorders such as obstructive sleep apnea. In previous work, we designed a custom-fit CPAP mask to address comfort and leakage issues patients often experience. This paper presents a method to create a finite element (FE) model to evaluate the fit of the custom-fit mask before fabrication. The model includes details such as a skull to represent the variable soft tissue thicknesses on the face, and two strap configurations, original and X. The model was tested on four subjects and results show that the X strap configuration results in a more even stress distribution, measured by standard deviation, on the face compared to the original strap, indicating better fit. The simulations also show gaps in the stress distribution that seem to correspond to areas of leakage based on two initial in vivo tests on two subjects. This simulation method proves to be a valuable tool for custom-fit mask development by allowing us to evaluate designs before fabrication.

Date: 2025
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DOI: 10.1080/10255842.2024.2341120

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