Nasal pillow is a sleep apnea mask, as sleep apnea surgery treatment, used for CPAP/BiPAP machine, with nasal cushion, nose cannula, ventilation tubing, and CPAP headgear, assembly of nasal pillow pad mask, plastic breathing tubing, and soft headgear.
Nasal Pillow known as pillow mask, nasal mask, CPAP mask, as a medical treatment for sleep apnea, widely used in hospital ICU and home, is made of medical liquid silicone by injection molding, the nasal pillow mask set with the comfortable silicone pillow pad mask, plastic elbow (vented/non-vented), mask frame, and assembly swivel and tube. Pillow mask, nasal mask, full face mask, and total face mask are the main types of CPAP masks, nasal pillow mask is better for people who have facial hair, nasal mask is better for side sleepers than full face & total face masks. As an experienced LIM medical silicone & plastic mask manufacturer, we also have clean room for assembly lines to assemble all masks parts together.
What Is Full Face CPAP Mask?
Full face mask with many medical parts: silicon forehead cushion, plastic mask frame, silicone mask cushion, plastic elbow, plastic swivel and tube, silicone valve and plug, plastic headgear clips and nylon headgear.
Ventilator CPAP Sleep Apnea Mask Nasal
Sleeping Disorder Treatment Full Face CPAP Mask
What Is Total Face CPAP Mask?
Total face mask covers the full face from forehead, nose, to mouth and face. The silicone cushion is not separated, it is over-molded with plastic mask frame by LIM – liquid injection molding, don’t need another forehead pad, the others parts are same as full face mask.
Custom Made Silicone CPAP Nasal Cushion Pillow Mask
Simple Mask Oxygen Nasal Cannula Mask
How To Manufacture Medical CPAP Mask?
The most important is medical grade materials, from silicone material to plastic material, to headgear nylon, 100% medical grade safe materials are the first step. For manufacturing mask cushion and forehead cushion, liquid silicone rubber injection molding is better. For simple silicone valve or plug, medical solid silicone compression molding is enough.
Mask Cushion By LIM – Liquid Silicone Rubber Injection Molding
Medical grade liquid silicone rubber (LSR) is an inorganic polymer formed from silicon (Si), oxygen (O), carbon (C), and hydrogen (H). The main chemical chain, called the backbone, is formed from silicon and oxygen, called siloxanes. To achieve ultimate properties, a catalyst is added during the curing process to form chemical bonds called cross-links between the backbone chains. Platinum and peroxide are the two chemicals used in this curing process, LSR is platinum cured silicone rubber. Platinum-cured silicone rubber offers advantages over peroxide-cured silicone rubber, including improved tensile and tear strength, improved clarity and consistency, and leaves no peroxide residue. LSR’s multifunctional properties originate from its siloxane bonds. This chain provides an inorganic backbone that does not interact with biomaterials and can incorporate organic chemical groups. Siloxane bonding also helps improve mechanical properties and strength. Biocompatibility is the best property of LSR material, always used for manufacturing medical products, such as nasal mask, mask cushion, cannula, menstrual cup, baby bottle, straw, baby pacifier, etc.
Besides molding silicone parts, if nasal face mask needs to combine together plastic mask frame with silicone mask cushion, because many plastic materials cannot resistant to high temperature, low temperature curing/vulcanizing – LSR injection molding is necessary, firstly need to form the plastic frame by plastic injection molding, then put the frame in LSR mold/tooling cavities to form the entire nasal mask, this processing is called over-molding. Medical Primer is required to apply to plastic frame border to better/steady connect with LSR silicone cushion. In the mold, the thermoplastic is cooled and solidified into the desired shape. When the plastic is completely cured, the mold is opened and the product is removed. Some post-processing is required, such as removing burrs on the product, surface treatment, etc.
The injection molding has a very simple process (no manual processes such as ingredients, mixing, cutting, and placement of materials in the HCR compression molding process are required, only one worker is required to remove the product), and the product is high precision (all manual procedures are replaced by machine before molding are required), high output (A/B liquid silicone rubber is mixed at a certain temperature and formed in a few seconds).
CPAP Mask Frame By Plastic Injection Molding
Medical injection molded parts are typically complex, high-precision, transparent, lightweight parts with tight tolerances that require excellent molding quality. Medical plastic injection molding processing: choose suitable plastic material, such as ABS, PP, PE, PVC, PC, etc. In the manufacture of medical devices, the material needs to meet certain biocompatibility and safety requirements. The plastic particles (raw material) are fed into the barrel of the injection molding machine. Under the heating of the electric heating ring, the plastic particles gradually melt and become fluid. When the plastic is completely melted, it is injected into a pre-made mold cavity through the screw of the injection molding machine. When the plastic is completely cured, the mold is opened and the product is removed. Some post-processing is required, such as removing burrs on the product, surface treatment, etc.
Mask Cushion/Half Mask By Silicone Compression Molding
The solid/liquid silicone raw material is placed in the mold, and then the silicone is filled into the mold cavity through high-temperature vulcanization and mechanical pressure, then cured and hardened, finally a silicone product of the desired shape is formed. This kind of silicone rubber is also called high-temperature cured silicone rubber (HCR). No matter which curing agent is used (peroxide curing system and platinum curing agent), it needs to be vulcanized at high temperature in order to be completely vulcanized and obtain ideal physical properties.
Sleep Apnea CPAP Mask Assembly
Preparing all accessories in clean room, full face mask assembly as an example, put the separate silicone mask cushion on plastic mask frame to fit well, put plastic elbow and tube to mask frame, and wear soft headgear through mask frame location holes.
Nasal Pillow
Nasal Pillow known as pillow mask, nasal mask, CPAP mask, as a medical treatment for sleep apnea, widely used in hospital ICU and home, is made of medical liquid silicone by injection molding, the nasal pillow mask set with the comfortable silicone pillow pad mask, plastic elbow (vented/non-vented), mask frame, and assembly swivel and tube. Pillow mask, nasal mask, full face mask, and total face mask are the main types of CPAP masks, nasal pillow mask is better for people who have facial hair, nasal mask is better for side sleepers than full face & total face masks. As an experienced LIM medical silicone & plastic mask manufacturer, we also have clean room for assembly lines to assemble all masks parts together.
What Is Full Face CPAP Mask?
Full face mask with many medical parts: silicon forehead cushion, plastic mask frame, silicone mask cushion, plastic elbow, plastic swivel and tube, silicone valve and plug, plastic headgear clips and nylon headgear.
Ventilator CPAP Sleep Apnea Mask Nasal
Sleeping Disorder Treatment Full Face CPAP Mask
What Is Total Face CPAP Mask?
Total face mask covers the full face from forehead, nose, to mouth and face. The silicone cushion is not separated, it is over-molded with plastic mask frame by LIM – liquid injection molding, don’t need another forehead pad, the others parts are same as full face mask.
Custom Made Silicone CPAP Nasal Cushion Pillow Mask
Simple Mask Oxygen Nasal Cannula Mask
How To Manufacture Medical CPAP Mask?
The most important is medical grade materials, from silicone material to plastic material, to headgear nylon, 100% medical grade safe materials are the first step. For manufacturing mask cushion and forehead cushion, liquid silicone rubber injection molding is better. For simple silicone valve or plug, medical solid silicone compression molding is enough.
Mask Cushion By LIM – Liquid Silicone Rubber Injection Molding
Medical grade liquid silicone rubber (LSR) is an inorganic polymer formed from silicon (Si), oxygen (O), carbon (C), and hydrogen (H). The main chemical chain, called the backbone, is formed from silicon and oxygen, called siloxanes. To achieve ultimate properties, a catalyst is added during the curing process to form chemical bonds called cross-links between the backbone chains. Platinum and peroxide are the two chemicals used in this curing process, LSR is platinum cured silicone rubber. Platinum-cured silicone rubber offers advantages over peroxide-cured silicone rubber, including improved tensile and tear strength, improved clarity and consistency, and leaves no peroxide residue. LSR’s multifunctional properties originate from its siloxane bonds. This chain provides an inorganic backbone that does not interact with biomaterials and can incorporate organic chemical groups. Siloxane bonding also helps improve mechanical properties and strength. Biocompatibility is the best property of LSR material, always used for manufacturing medical products, such as nasal mask, mask cushion, cannula, menstrual cup, baby bottle, straw, baby pacifier, etc.
Besides molding silicone parts, if nasal face mask needs to combine together plastic mask frame with silicone mask cushion, because many plastic materials cannot resistant to high temperature, low temperature curing/vulcanizing – LSR injection molding is necessary, firstly need to form the plastic frame by plastic injection molding, then put the frame in LSR mold/tooling cavities to form the entire nasal mask, this processing is called over-molding. Medical Primer is required to apply to plastic frame border to better/steady connect with LSR silicone cushion. In the mold, the thermoplastic is cooled and solidified into the desired shape. When the plastic is completely cured, the mold is opened and the product is removed. Some post-processing is required, such as removing burrs on the product, surface treatment, etc.
The injection molding has a very simple process (no manual processes such as ingredients, mixing, cutting, and placement of materials in the HCR compression molding process are required, only one worker is required to remove the product), and the product is high precision (all manual procedures are replaced by machine before molding are required), high output (A/B liquid silicone rubber is mixed at a certain temperature and formed in a few seconds).
CPAP Mask Frame By Plastic Injection Molding
Medical injection molded parts are typically complex, high-precision, transparent, lightweight parts with tight tolerances that require excellent molding quality. Medical plastic injection molding processing: choose suitable plastic material, such as ABS, PP, PE, PVC, PC, etc. In the manufacture of medical devices, the material needs to meet certain biocompatibility and safety requirements. The plastic particles (raw material) are fed into the barrel of the injection molding machine. Under the heating of the electric heating ring, the plastic particles gradually melt and become fluid. When the plastic is completely melted, it is injected into a pre-made mold cavity through the screw of the injection molding machine. When the plastic is completely cured, the mold is opened and the product is removed. Some post-processing is required, such as removing burrs on the product, surface treatment, etc.
Mask Cushion/Half Mask By Silicone Compression Molding
The solid/liquid silicone raw material is placed in the mold, and then the silicone is filled into the mold cavity through high-temperature vulcanization and mechanical pressure, then cured and hardened, finally a silicone product of the desired shape is formed. This kind of silicone rubber is also called high-temperature cured silicone rubber (HCR). No matter which curing agent is used (peroxide curing system and platinum curing agent), it needs to be vulcanized at high temperature in order to be completely vulcanized and obtain ideal physical properties.
Sleep Apnea CPAP Mask Assembly
Preparing all accessories in clean room, full face mask assembly as an example, put the separate silicone mask cushion on plastic mask frame to fit well, put plastic elbow and tube to mask frame, and wear soft headgear through mask frame location holes.
