3DMyMask 3D printing silicone masks for premature infants

3DMyMask, a collaborative initiative spearheaded by Digifab, IAM3DHUB and the Hospital Clínic de Barcelona, is leveraging 3D technologies, like 3D scanning and 3D printing, to develop custom silicone masks for premature infants. The project, nominated as a finalist in the Rookie category of the Formnext Awards 2025, aims to minimize the risk of respiratory distress in neonatal intensive care units.

There are many possible complications that can arise in neonatal care, but among the most prevalent are respiratory issues. Reportedly up to 75% of premature babies in neonatal intensive care require non-invasive ventilation, an intervention that requires the use of very small masks. Today, the majority of ventilation masks used come in standard sizes and are prone to air leaks and—in worse cases—pressure injuries and craniofacial deformations.

There is thus an effort to customize these masks for better fit and function. One such effort is coming from Barcelona, where the Hospital Clínic de Barcelona has been investigating the use of 3D printing to create patient-specific masks from silicone. This research is culminating in the 3DMyMask project, which also includes partners Digifab, the AM node of the Catalan Society of Technology; IAM3DHUB, a European AM accelerator; silicone 3D printing company Lynxter; 3D scanning specialist Shining 3D; silicone materials company Elkem; silicone AM company 3Deus; and silicone rubber molds company SiOCAST.

The initiative is leveraging cutting-edge technologies, including silicone 3D printing, to create custom-fit ventilation masks for premature infants. The workflow sounds simple enough: infants undergo 3D facial scanning, and then digital models of the masks are tailored to their face size and shape before being reproduced out of biocompatible silicone on a 3D printer. The result is a ventilation mask that can reduce air leakage by up to 60%—measured in neonatal simulators—while improving pressure profiles and fit.

“3DMyMask represents a scalable, clinically relevant and technologically advanced solution that positions neonatal care at the forefront of personalization and innovation,” the project says. “Ultimately, it is a call to give the most fragile patients the innovation they deserve. Neonates and preterm infants, too often left behind in technological progress, must be heard and supported from the very first breath.”

3DMyMask, which has at its foundation the clinical insights of the Hospital Clínic de Barcelona, is one of three finalists in the Rookie Award category at the upcoming Formnext Awards. Other finalists in the group are Fidentis GmbH, which has created the first commercial multi-material additive manufacturing solution for dental technology, and Tesseract Technologies B.V., a Dutch startup that has developed accessible linear motors for large-format FDM 3D printers. The winner will be announced on November 20, 2025 at the Formnext Awards ceremony in Frankfurt.