Systems and methods for providing custom masks for use in a breathing assistance system

1. A method for selecting a facial seal for use in a breathing assistance system, comprising:

obtaining a plurality of three-dimensional contour data sets, each three-dimensional contour data set comprising data from images of three-dimensional exterior facial contours of a plurality of test subjects having a common demographic characteristic, such that each three-dimensional contour data set corresponds to one or more different demographic characteristics;

using a computer, processing each three-dimensional contour data set to generate a characteristic three-dimensional structure for a sample facial seal corresponding to that three-dimensional contour data set;

for each three-dimensional contour data set, fabricating a sample facial seal based on the characteristic three-dimensional structure generated based on that three-dimensional contour data set, such that a plurality of sample facial seals are fabricated, each having a different shape corresponding to one or more different demographic characteristics;

obtaining a set of data representing a three-dimensional structure of an exterior surface contour of a patient's face; and

automatically selecting a particular one of a plurality of sample facial seals having different shapes, the particular facial seal selected to substantially conform to the patient's face based at least on the set of facial data, including:

using a computer, automatically comparing the set of facial data to the plurality of three-dimensional contour data sets, each three-dimensional contour data set representing a three-dimensional structure of one of the plurality of sample facial seals; and

using the computer, automatically selecting the particular facial seal from the plurality of sample facial seals based at least on the comparison.

2. A method according to claim 1 , wherein obtaining data from images of three-dimensional exterior facial contours of a plurality of test subjects comprises using an image capturing technique selected from a group consisting of laser scanning, stereo photography, and tactile imaging.

3. A method according to claim 1 , wherein a facial seal comprises a mask cushion.

4. A method according to claim 1 , wherein the one or more demographic characteristics are selected from a group consisting of race, ethnicity, geographic origin, height, weight, and age.

5. A method for making sample facial seals comprising:

selecting a sample of test subjects having a common demographic characteristic;

capturing an image of a three-dimensional structure of an exterior surface contour of a face of each test subject;

translating the images into a set of sample data corresponding to the common demographic characteristic;

storing the set of sample data in a database;

using a computer, processing the sample data set from the plurality of test subjects in order to automatically generate a characteristic three-dimensional structure for a sample facial seal based at least on the set of sample data; and

fabricating the sample facial seal based on the generated characteristic three-dimensional structure such that the sample facial seal is designed for a plurality of individuals having the demographic characteristic.

6. A method, comprising:

obtaining a plurality of three-dimensional contour data sets, each three-dimensional contour data set comprising data from images of three-dimensional exterior facial contours of a plurality of test subjects having a common demographic characteristic, such that each three-dimensional contour data set corresponds to one or more different demographic characteristics;

using a computer, processing each three-dimensional contour data set to generate a characteristic three-dimensional structure for a sample facial seal corresponding to that three-dimensional contour data set; and

for each three-dimensional contour data set, fabricating a sample facial seal based on the characteristic three-dimensional structure generated based on that three-dimensional contour data set, such that a plurality of sample facial seals are fabricated, each having a different shape corresponding to one or more different demographic characteristics;

using the plurality of sample facial seals to provide multiple options for selection of a particular sample facial seal for a patient.