Vayu Sleep creates custom CPAP masks by converting a smartphone‑captured 3‑D facial scan into an AI‑generated design that optimizes seal geometry and material thickness. The masks are produced on a robotic CNC/additive manufacturing line in a lightweight, hypoallergenic polymer and shipped ready for use with any standard CPAP machine. The company sells the masks directly to patients and to sleep clinics on a one‑time purchase model.
Funding
Funding not disclosed
Founders
Product
Problem
Patients with obstructive sleep apnea frequently discontinue CPAP therapy because off‑the‑shelf masks are poorly sized, causing pressure points, air leaks, and overall discomfort. The resulting low adherence undermines treatment efficacy and increases long‑term health risks.
Solution
Vayu Sleep delivers a fully personalized CPAP mask that is engineered from a 3‑D facial scan captured with a smartphone camera. Proprietary AI algorithms convert the scan into a parametric model, optimizing seal geometry and material thickness for each user’s anatomy. The model drives a robotic manufacturing line that fabricates the mask in a lightweight, hypoallergenic polymer within days. The finished device is shipped directly to the patient and is compatible with any standard CPAP machine, eliminating the need for clinic‑based fittings and reducing therapy dropout rates.
Target Audience
The primary customers are adult patients diagnosed with obstructive sleep apnea who require CPAP therapy, as well as sleep clinics and durable‑medical‑equipment (DME) providers seeking a higher‑adherence mask solution.
Features
- Mobile photogrammetry workflow: patients capture a high‑resolution facial scan using a phone camera in under two minutes.
- AI‑powered generative design engine that tailors mask curvature, vent placement, and strap geometry to individual facial topography.
- Robotic CNC/additive manufacturing platform that produces the mask with sub‑millimeter tolerances and consistent material properties.
- Rapid production pipeline (typically 48–72 hours) from scan upload to dispatch, enabling same‑day order fulfillment.
- Seamless integration with existing CPAP hardware via standard hose connectors and pressure ports.
- Secure, HIPAA‑compliant data handling for scanned images and design files, stored on encrypted cloud servers.
- Lightweight, medical‑grade silicone‑coated polymer that provides a breathable, skin‑friendly seal and reduces pressure‑point irritation.