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FlexAire Mask
Sunrise Medical

Continuous Positive Airway Pressure (CPAP) sleep therapy systems are used by sufferers of obstructive Sleep Apnea. The FlexAire mask revolutionizes patient fit and comfort through an adjustable air-filled cushion that comfortably forms to a variety of face sizes. The FlexAire design facilitates quick changes and a variety of user preference settings.

From the early stages Zukun brainstormed new approaches for a universal fit sleep apnea mask. The initial concept generation addressed issues with comfort, ease of use, and appearance i.e. how the user feels about wearing a mask around the house. Concept refinement led to mechanical problem solving and testing, prototyping, engineering, Pro-Engineer modeling, and finally production intent design specifications.

The FlexAire mask has been praised for its innovative features, its ability to fit a very wide range of facial profiles, its ease of use for both the patient and clinician, and its cost effectiveness.

Services Provided:
• ID Concept Exploration
• ID Concept Refinement
• Mechanical Engineering
• Production Intent Resolution
• Prototyping
• Testing and Refinement
• Production Release Design

(Left) Product Photo
(Right) Assembly Concept