System and method for forming a custom medical mask using an orientation device

1. A method of forming a custom medical mask for a particular user, comprising:

while an oral appliance is positioned in the particular user's mouth to receive the particular user's teeth and is coupled to an orientation device using a post of the oral appliance, applying an impression material over the orientation device and the particular user's face including at least the particular user's mouth and a portion of the particular user's nose surrounding the particular user's nostrils, such that the impression material conforms to the orientation device and to the particular user's unique facial features;

removing the impression material from the particular user's face together with the orientation device,

creating a cast of the particular user's face using the impression material together with the orientation device as a mold, such that the cast conforms to the impression material and the orientation device; and

applying a deformable material to the cast of the particular user's face to form a custom medical mask for the particular user, such that the deformable material conforms to the cast;

wherein the custom medical mask is custom-fitted to the particular user's unique facial features and custom-oriented to the particular user's teeth; and

wherein the orientation device comprises at least one breathing passage configured to allow the particular user to breathe through the particular user's mouth when the particular user's mouth is covered with the impression material.

2. The method of claim 1 , further comprising inserting into the orientation device a second post corresponding to the oral appliance post, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the second post within the orientation device.

3. The method of claim 2 , further comprising coupling a locking mechanism to the second post, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the locking mechanism.

4. The method of claim 1 , further comprising removing the impression material from the particular user's face together with the orientation device and the post of the oral appliance, such that when the deformable material is applied to the cast the deformable material further conforms to the post of the oral appliance.

5. The method of claim 4 , further comprising coupling a locking mechanism to the post of the oral appliance, prior to applying the deformable material, such that when the deformable material is applied to the cast the deformable material further conforms to the locking mechanism.

6. The method of claim 1 , wherein the orientation device comprises:

an elongated tubular member configured to receive the oral appliance post; and

a restraining structure configured to limit movement of the orientation device relative to the oral appliance.

7. The method of claim 6 , wherein the restraining structure comprises a flange projecting from the elongated tubular member and configured to be positioned between the particular user's lips and teeth.

8. The method of claim 1 , wherein the deformable material comprises a thermoplastic polymer and is heated to transition to a deformable state prior to applying the deformable material to the cast.

9. The method of claim 8 , wherein the thermoplastic polymer comprises a polycaprolactone polymer.

10. The method of claim 1 , further comprising:

creating openings in the custom medical mask corresponding to the particular user's nostrils; and

coupling a fitting for a clinical gas delivery system to the custom medical mask for supplying a gas to the particular user's nostrils through the openings in the custom medical mask.

11. A method for forming a cast for use in forming a custom medical mask for a particular user, comprising:

while an oral appliance is positioned in the particular user's mouth to receive the particular user's teeth and is coupled to an orientation device using a post of the oral appliance, applying an impression material over the orientation device and the particular user's face including at least the particular user's mouth and a portion of the particular user's nose surrounding the particular user's nostrils, such that the impression material conforms to the orientation device and to the particular user's unique facial features;

removing the impression material from the particular user's face together with the orientation device; and

creating a cast of the particular user's face using the impression material together with the orientation device as a mold, such that the cast conforms to the impression material and the orientation device;

wherein the orientation device comprises at least one breathing passage configured to allow the particular user to breathe through the particular user's mouth when the particular user's mouth is covered with the impression material.

12. The method of claim 11 , wherein the orientation device comprises:

an elongated tubular member configured to receive the oral appliance post; and

a restraining structure configured to limit movement of the orientation device relative to the oral appliance.

13. The method of claim 12 , wherein the restraining structure comprises a flange projecting from the elongated tubular member and configured to be positioned between the particular user's lips and teeth.