3D-printed mouthpiece customised for sleep apnoea sufferers

A new 3D-printed device, developed by CSIRO in collaboration with dental company Oventus, is set to end the suffering for thousands of sleep apnoea patients.

Sleep apnoea occurs when the air passage in the throat becomes blocked during sleep and causes people to stop breathing. An estimated one million Australians suffer from the disorder - a number that is expected to increase - which can lead to high blood pressure, stroke, irregular heartbeats, heart attacks and diabetes.

The existing treatments for sleep apnoea include devices that push the lower jaw forward to open up the airway or, in more severe cases, a face mask which creates a continuous flow of air. The latest method uses a 3D scanner to map each patient’s mouth, from which the team can create the new mouthpiece.

The device has a ‘duckbill’ which extends from the mouth like a whistle and divides into two separate airways. It allows air to flow through to the back of the throat, avoiding obstructions from the nose, the back of the mouth and the tongue.

“The new 3D-printed mouthpiece bypasses all obstructions by having airways that deliver air to the back of the throat and it will also stop patients from snoring,” said Oventus CEO Neil Anderson.

Anderson added that the device is only used on the top teeth, making it “more compact and far more comfortable”. Printed from titanium and coated with a medical-grade plastic, the mouthpiece is customised for each patient.

“When Oventus came to CSIRO with this idea, we were really excited,” said CSIRO 3D printing expert John Barnes. “The possibilities of 3D printing are endless and the fact that we can now design and print a completely customised mouthpiece for patients is revolutionary. 

“It’s an exciting prospect for people suffering from the debilitating disorder and the design offers significant benefits which cannot be achieved with more traditional manufacturing techniques.”

The device is expected to be available to patients next year.

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