FOAM CUSHION RESPIRATORY APPARATUS

The present invention discloses an apparatus for forming a mask structure for a respiratory treatment comprising: a first mould (9040) comprising a portion configured to receive a foam cushion (9002); an inner moulding core (9050) that has a first ridge and a shape corresponding to a mask frame component, wherein the inner moulding core attaches to the first mould such that the first ridge contacts the foam cushion; and a second mould comprising a shaped portion that has a second ridge and a shape corresponding to the mask frame component, wherein the second mould (9060) attaches to the first mould such that the second ridge (9065) contacts the foam cushion, wherein when material is injected into the apparatus, the injected material bonds to a first portion of the foam cushion and the inner moulding core shapes an inner portion of the mask frame component and the shaped portion of the second mould shapes an outer portion of the mask frame component to form the mask frame component, wherein the first ridge and the second ridge prevent the injected material from spreading to parts of the foam other than the first portion of the foam.