Manufactured to shape headgear and masks

A mask system for use in treating a patient for sleep disordered breathing, comprising:

• a mask adapted to seal against the patient's face thereby forming a breathing cavity to deliver pressurized air to the patient's airways;
• and
• a headgear assembly to support the mask in position on the patient's face for positive pressure treatment of the patient, the headgear assembly including:
• at least one headgear component including spacer fabric having an inner layer, an outer layer and spacer threads joining the inner layer and the outer layer, the inner layer being adapted to interface with the patient and the outer layer forming a non-patient contacting side of the at least one headgear component,
• the inner layer having a first characteristic associated with at least one property and the outer layer having a second characteristic associated with the at least one property, the first characteristic being different from the second characteristic,
• each spacer thread having a first point along its longitudinal length connected to the inner layer and a second point along its longitudinal length connected to the outer layer, the first point being spaced apart from the second point in a thickness direction of the spacer fabric,
• wherein lengths of the spacer threads from the respective first points to the respective second points vary along the at least one headgear component to vary a thickness of the spacer fabric so as to form thinner regions and thicker regions of the spacer fabric, and
• wherein a density of the spacer threads varies along the at least one headgear component to form a first area and a second area, the first area being more dense than the second area, the first area having increased stiffness as compared to the second area and the second area having increased flexibility as compared to the first area.