This document summarizes the development of a convertible CPAP mask kit for children. Existing pediatric CPAP masks do not fit children well and fail to address their unique needs. The new design allows users to switch between a nasal and full face mask. It also offers different strap configurations to improve fit. Prototypes included a convertible mask, strap attachments, and silicone gel molds. The goal is to create a customizable mask that grows with the child and meets their individual fit and sensory preferences. Future work includes improving the gel mold and preventing overtightening of straps.

1. CPAP for Kids
Process Book
Kathleen Jordan, Sarah Selim, Viral Shah,
and Marie Stauffer
Fall 2016

2. Table of Contents
1. Executive Summary
2. Background
3. Concept Development
4. Prototyping- Convertible Mask
5. Prototyping- Strap Configurations
6. Prototyping- Strap Attachment
7. Prototyping- Silicone Gel
8. Final Concept

3. Executive Summary
Pediatric CPAP masks do not meet the unique needs of children because the masks do not fit their different facial shape or
address differing sensory issues. In order to address these issues, a new mask needs to be designed that is customizable,
adaptable, and unique to each child’s face and needs. By working with Dr. Gary Montgomery, the medical director of the
sleep center for Children’s Healthcare of Atlanta (CHOA), and caregivers of non-verbal children, we were able to gather
information about what they considered the most important design changes. In order to achieve this new design, a
convertible CPAP mask kit was created. By designing the convertible mask, a user can switch between a nasal CPAP mask
and a full face CPAP mask in order to accommodate their preferences each night and choose any strap configuration to
meet their personal preferences.

4. Background
Continuous positive airway pressure (CPAP) machines
deliver positive end-expiratory pressure to the patient’s
airways to raise inspiratory pressure and prevent the
airways from collapsing.
Pediatric CPAP masks are currently in low availability
and do not suit the wide range of growing children who
have different physiological needs than adults. Interviews
with doctors and caregivers show that current products
are ill-fitting and do not grow with the child.
The picture to the left shows how current pediatric masks
do not adequately fit children and often fall off during the
night, this results in the child not receiving the treatment
they need.

5. Concept Development- Users’ Complaints
● Not given any selection of mask type
○ Vendor brings only 1-2 masks for child to try on
before buying
○ Leaves the child with limited number of options
to satisfy a large variety of personal preferences
■ Nasal masks versus full face masks
■ Headgear/ strap configurations
● Size does not fit
○ Not many products designed for kids
○ Usually have to wear a women’s small
● Morning marks
○ Caused by over-tightening headgear
○ Difficult to determine proper tightness because
mask is ill-fitting to their face

6. Concept Development
● One modular kit that offers the user all
possible configurations available on the
market
○ Convertible mask
■ Easily switch between a full face mask and a
nasal mask
○ Strap configurations
■ Every mask fits with different strap
configurations
■ Straps are adjustable to child’s head size

7. Prototypes- Convertible Mask
Mask kit comes with top half of the mask that fits into both a
nasal bottom and a full face bottom, held together by latches
Top half of the mask
Nasal bottom half of the mask
Full face bottom half of the mask
Top half of mask with “horn”

8. Prototypes- Strap Configurations
Flat-lay of different strap configurations. (Top) “Butterfly” strap configuration. (Bottom) “Horn” strap
configuration“Butterfly” strap configuration attached to mask
“Horn” strap configuration attached to mask

9. Prototypes- Strap Attachments
Magnet holder connected to straps
Magnet holder on bottom pieces of the mask
“Horn” that connects the “horn” strap
configuration to the top of the mask

10. Prototypes- Silicone Gel
Nasal mask with silicone mold
Full face bottom, nasal bottom, and top mask pieces with full face and nasal silicone molds

11. Final Concept
Full face mask with “butterfly” straps and silicone mold Nasal mask with “horn” straps

12. Future Directions
● Improve gel
○ Silicone gel molds to the face correctly
○ Is too inflexible when it dries to be comfortable on the face
○ Look for some type of thermoplastic that will retain its plasticity after the initial molding
● Prevent over tightening
○ Create and incorporate a visual cue to alert the child when the straps are tightened to the
correct amount
● CHOA interviews
○ Begin phone interviews with 100 patients