Programa del congreso

Current neonatal non-invasive ventilation (NIV) masks are available in limited standard sizes, often failing to fit their unique facial anatomy. This poor fit increases the risk of air leaks, displacement and pressure-related skin injuries, reducing the effectiveness of respiratory support. This project aimed to develop custom-made NIV masks precisely adapted to neonatal morphology. The workflow combined facial scanning, parametric design and direct silicone 3D printing. Facial data were captured with a portable, non-contact 3D scanner suitable for safe use inside incubators. A modular parametric design was implemented, consisting of a fixed base compatible with standard ventilator systems and a customizable nasal contour tailored to each patient. This enables fast adaptation while maintaining a secure connection to hospital equipment. Masks were produced using stereolithography (SLA) with Silicone 40A, a newly introduced material that offers softness, flexibility, and mechanical strength suitable for direct skin contact. Direct printing eliminated molds, reducing production time and simplifying manufacturing. Initial prototypes were successfully connected to the ventilator and underwent a qualitative assessment on a neonatal manikin. Future work should include functional testing to evaluate leakage, pressure distribution and clinical performance. This work demonstrates the feasibility of fast, patient-specific devices and the clinical potential of silicone 3D printing in neonatal respiratory care.