Foam cushion respiratory apparatus

An apparatus for forming a mask structure for a respiratory treatment, the apparatus comprising:

• a bottom mould comprising a portion configured to receive a foam cushion;
• an inner moulding core comprising an outer surface and an inner surface, wherein the outer surface has a convex shape corresponding to a shape of an inner surface of a mask frame component, wherein the inner moulding core has a ridge at an edge of the outer surface of the inner moulding core and the inner moulding core is configured to fasten to the bottom mould such that the ridge of the inner moulding core compresses the foam cushion;
• and
• a top mould comprising a shaped portion, wherein the shaped portion has a concave shape corresponding to a shape of an outer surface of the mask frame component, wherein the top mould has an outer clamping ridge at an edge of the shaped portion, the top mould is configured to fasten to the bottom mould such that the outer clamping ridge compresses the foam cushion, and the shaped portion of the top mould is oriented toward the outer surface of the inner moulding core,
• wherein material is injectable into the apparatus such that the injected material bonds to a first portion of the foam cushion, the outer surface of the inner moulding core shapes the inner surface of the mask frame component, and the shaped portion of the top mould shapes the outer surface of the mask frame component to form the mask frame component, and
• wherein the ridge of the inner moulding core and the outer clamping ridge of the top mould each compress the foam cushion to prevent the injected material from spreading to parts of the foam cushion other than the first portion of the foam cushion.