Facial mask with custom-manufactured cushion element, and associated method

A method of forming at least a portion of a mask that is structured to deliver a flow of breathing gas to the airways of a patient and that is structured to engage at least a portion of the face of the patient in the vicinity of the airways, the method comprising:

• employing at least a portion of a data set that is stored on a machine-readable storage medium and that is representative of the shape of at least a portion of the face in generating a configuration for a cushion element of the mask, the cushion element being structured to extend from a support of the mask and to have an engagement end opposite the support that corresponds with the shape of the at least portion of the face;
• subjecting a workpiece that is in the form of a flat sheet of mesh which is formed at least in part of metallic fibers to a heating operation that heats the workpiece to at least a predetermined temperature;
• and
• subjecting the heated workpiece to a formation operation that employs a variable mold apparatus having a plurality of movable mold elements that are positioned in accordance with the configuration and that apply confronting compressive forces to the heated workpiece to cause at least a portion of the heated workpiece to be formed into the cushion element having the engagement end;
• and
• cutting the workpiece to separate the cushion element from a remaining portion of the workpiece.