The New Hotness

Mary cut out a simple cloth liner for her ResMed F20 CPAP mask (a.k.a. “cushion”) and snipped away at the fabric until it felt about right. I scanned the result and turned it into a bitmap mask (which is entirely different from a CPAP mask):

Mask liner - scanned — Mask liner – scanned

Given that as a start:

Import the scanned image into LightBurn
Fair a few curves around the perimeters by hand, rather than attempting to trace the thing
Rationalize the sizes
Make it symmetric
Cut a few prototypes while tweaking the fit

Which leads to a pattern like this:

CPAP Mask Liner - F20 knit - spline fit — CPAP Mask Liner – F20 knit – spline fit

The rectangular upper part forms a simple eyeshade that also keeps minor leaks from disturbing her sleep. Your mileage may vary, depending on how much you toss and turn during the night.

We found the fit depends on the fabric, with woven fabric requiring a taller opening:

CPAP Mask Liner - F20 knit woven - LB layout — CPAP Mask Liner – F20 knit woven – LB layout

The engraved legend verifies I used the proper design for the fabric:

Laser cut CPAP Mask Liner - F20 - knit fabric — Laser cut CPAP Mask Liner – F20 – knit fabric

The opening has tabs holding it in place while cutting, at least until we get this down to a routine.

Then make enough for a while:

Laser cut CPAP Mask Liner - F20 - production — Laser cut CPAP Mask Liner – F20 – production

The usual woodstove odor vanishes after half a day sitting atop the clothes washer. Putting them in a mesh bag and tossing them into the regular wash refreshes them after use.

The LightBurn SVG layouts as a GitHub Gist:

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view raw CPAP Mask Liner – F20 knit woven – LB layout.svg hosted with ❤ by GitHub

The New Hotness

DIY CPAP Mask Liner