Abstract: There is provided a method of manufacturing a sealing member (42). The method comprises the steps of: (a) providing a mould having a cavity, a polymer injection port and a gas inlet port (38); (b) injecting a polymer and a blowing agent through the polymer injection port (28) into the cavity of the mould; and (c) introducing gas through the gas inlet port (38) into the cavity of the mould, to form a sealing member (42). The sealing member (42) comprises an internal chamber (44) at least partially bounded by a resiliently deformable enclosing wall formed of the polymer, the enclosing wall including an external surface, the external surface having a form that is determined by the cavity of the mould.

Abstract: There is provided a method of manufacturing a sealing member for a respiratory interface device. The method comprises the steps of: (a) providing a mould having a cavity, a polymer injection port and a gas inlet port; (b) injecting a polymer through the polymer injection port into the cavity of the mould; and (c) introducing gas through the gas inlet port into the cavity of the mould, to form a sealing member of the respiratory interface device, thereby forming a sealing member of the respiratory interface device. The sealing member of the respiratory interface device comprises an internal chamber at least partially bounded by a resiliently deformable enclosing wall formed of the polymer, the enclosing wall including a patient-contacting surface, the patient-contacting surface having a form that is determined by the cavity of the mould and provides an anatomical fit with a patient.