Method of making applicator with precision eye opening

A method of making a face mask for a face of a human user can include determining a lower eye region bound and determining an upper eye region bound by locating an upper bound of the eyeball as determined by a peak point of an arc of concavity in an upper eyelid of the at least one eye when the eye is closed. The method can also include setting a first anchor point about 0 mm to about 10 mm below the lower eye region bound, and setting a second anchor point about 0 mm to about 10 mm above the upper eye region bound; and defining at least one eye opening for a face mask having first edge that intersects the first anchor point and a second edge that intersects the second anchor point.

FIELD OF THE DISCLOSURE

The disclosure relates to masks having custom openings and methods of creating mask having custom openings defined therein.

BACKGROUND OF THE DISCLOSURE

Agents for affecting target structures are well known. Temperature affects may be induced by the application of hot or cold agents to the target. The appearance of a target may be affected by cosmetic and decorative agents. Electric current, voltages, and electric and magnetic fields may be applied to a target using local applicators. For biological targets, surface properties may be impacted by the use of topical application of moisturizers, medicaments and other treatment actives.

The effectiveness of the active agent may be impacted by the nature of the applicator available to facilitate the interaction of the active agent with the target structure. Typical applicators are less than precise with respect to their conformance to the target structure and the use of one-size, or a few sizes, fits all tends to compromise the actual performance of the active agent. In particular, conventional one-size fits all applicators for facial products, for example, typically have universally large eye and lip openings to accommodate variations in user's features. As a result, such applicators are ineffective at applying an active agent in the region of the eye or the lips in many individuals. Additionally, given the general poor fit and registration of conventional applicators on the face, alignment of eye and lip openings can be particularly difficult and lead to discomfort by the user.

SUMMARY OF THE DISCLOSURE

In accordance with embodiments, applicators having custom sized openings and methods of making the same can include applicators with agents for affecting target structures, for example, beauty masks.

In accordance with embodiments, a method of making a face mask for a face of a human user can include determining a lower eye region bound. For example, the lower eye region bound can be determined by locating a position of one or more of a lowest extent of one or more lower eyelashes of the at least one eye when the eye is open, a lower bound of the eyeball as determined by a peak point of an arc of concavity in the lower eyelid of the at least one eye when the eye is closed, and a lowest extent of one or more upper eyelashes of the at least one eye when the eye is closed. The method can further include determining an upper eye region bound. For example, the upper eye region bound can be determined by locating an upper bound of the eyeball as determined by a peak point of an arc of concavity in an upper eyelid region of the at least one eye when the eye is closed. The eye height is defined by the distance between the lower eye region bound and the upper eye region bound. The method also includes defining the at least one eye opening such that, when the mask is fitted to the face, the first edge is disposed 0 mm to about 10 mm below the lower eye region bound and the second edge is disposed 0 mm to about 10 mm above the upper eye region bound. The method can also include creating the face mask having the at least one eye opening.

In accordance with embodiments, a method of making a face mask for a face of a human user can include determining a lower eye region bound. For example, the lower eye region bound can be determine by locating a position of one or more of a lowest extent of one or more lower eyelashes of the at least one eye when the eye is open, a lower bound of the eyeball as determined by a peak point of an arc of concavity in the lower eyelid of the at least one eye when the eye is closed, and a lowest extent of one or more upper eyelashes of the at least one eye when the eye is closed. The method can further include determining an upper eye region bound. For example, the upper eye region by can be determined by locating an upper bound of the eyeball as determined by a peak point of an arc of concavity in an upper eyelid region of the at least one eye when the eye is closed. The method can also include setting a first anchor point about 0 mm to about 10 mm below the lower eye region bound, and setting a second anchor point about 0 mm to about 10 mm above the upper eye region bound. The method also includes defining at least one eye opening for a face mask having first edge that intersects the first anchor point and a second edge that intersects the second anchor point. The method can further include creating the face mask having the at least one eye opening. In embodiments, the first and/or the second edge can be curved.

In accordance with embodiments, a method of making a face mask for a face of a human user can include a) determining on a digital geometric representation of the face including at least one eye each of a position of a medial canthus, a position of a lateral canthus, a lower eye region bound, and an upper eye region bound. For example, the lower eye region bound can be defined by one or more of a lowest extent of one or more lower eyelashes of the at least one eye when the eye is open, a lower bound of the eyeball as determined by a peak point of an arc of concavity in the lower eyelid region of the at least one eye when the eye is closed, and a lowest extent of one or more upper eyelashes of the at least one eye when the eye is closed. For example, the upper eye region bound can be defined by upper bound of the eyeball as determined by a peak point of an arc of concavity in an upper eyelid of the at least one eye when the eye is closed. The method can further include b) setting a first anchor point about 1 mm to about 10 mm outboard (taking the eye center as reference point) from the medial canthus, c) setting a second anchor point about 1 mm to about 10 mm outboard from the lateral canthus, d) setting a third anchor point spaced about 0 mm to about 10 mm below lower eye region bound, and e) setting a fourth anchor point spaced about 0 mm to about 10 mm above the upper eye region bound. The method can also include f) defining at least one eye opening having a first edge defined by a first curve connecting the first, third, and second anchor points, and a second edge defined by a second curve connecting the first, fourth, and second anchor points. The method can include creating the face mask having the defined at least one eye opening.

In any of the foregoing methods or methods disclosed herein, two eye openings can be defined, repeating the steps of the methods for each eye.

In embodiments, a method can include or further include determining a position of an outermost edge of each of first and second nostrils, setting a first nose anchor point about 0 mm to about 10 mm from the outermost edge of the first nostril, setting a second nose anchor point about 0 mm to about 10 mm from the outermost edge of the second nostril, and defining a nose opening having side edges that intersect with the first and second nose anchor points. In various embodiments, the method can include or further includes determining a position of the base of the columella, determining a position of the tip of the nose, setting a third nose anchor point about 0 mm to about 10 mm from the position of the base of the columella and a fourth nose anchor point 0 mm to about 10 mm from the position of the tip of the nose, and defining a nose opening to have a circumferential edges that intersects with each of the first, second, third, and fourth anchor points. In embodiments, a method can include or further includes determining an uppermost point of at least one of the first and second nostrils; setting a fifth nose anchor point about 0 to about 10 mm from the base of the columella, setting a sixth nose anchor point about 0 to about 10 mm from one of the uppermost points of the first and second nostrils and defining the mask to have a nose opening with top and bottom edges that intersect with the fifth and sixth nose anchor points. In various embodiments, the fifth nose anchor point can be the uppermost one of the uppermost point of the first and second nostrils. In various embodiments, the fifth nose anchor point can be the uppermost point of the first nostril and a fifth nose anchor point can be defined at the upper most point of the second nostril. In various embodiments, the nose opening can be defined such that the edges of the opening interest with two anchor points, three anchor points, four anchor points, five anchor points, six anchor points, or more.

In accordance with embodiments, method can include or further include defining a mouth opening. The method can include determining a position of an upper point of the vermillion border and determining a position of a lower point of the vermillion border. The method can further include setting a first lip anchor point about 0 mm to about 10 mm from the upper point of the vermillion border, and setting a second lip anchor point about 0 mm to about 10 mm from the lower point of the vermillion border. The method can also include and defining a mouth opening having a first edge that intersects with the first lip anchor point and a second edge that intersects with the second lip anchor point. In various embodiments, the method can include or further include determining positions of each of the first and second corners of the mouth, setting a third lip anchor point about 0 mm to about 10 mm from the first corner, setting a fourth lip anchor point about 0 mm to about 10 mm from the second corner, and defining a mouth opening having a first edge that intersects the first, third, and fourth anchor points, and a second edge that intersects the second, third, and fourth anchor points.

DETAILED DESCRIPTION OF THE DISCLOSURE

In one aspect the face mask comprises at least one opening having a shape determined according to a digital geometric representation, or other created digital geometric representation of a target structure.

As used herein the term flexible means that a three-dimensional geometry of an element or the applicator in its entirety may be altered without any permanent deformation of the element's geometry. Applicator is also interchangeable used herein with “face mask” or “mask.”

Referring toFIGS.1A-1C, the eye region10of the human face includes an eyeball12covered in part, on the bottom by a lower eyelid14and on the top by an upper eyelid16. The lower and upper eyelids14,16each have an inner eyelid liner18,20adjacent the eyeball12. From the eyelid liners18,20extend lower and upper eyelashes22,24. The eye region10further includes a medial canthus26and a lateral canthus28. The eyebrow30is situated above the upper eyelid16.

The bounds of the eyeball12can be visually determined externally on the upper and lower eyelids14,16. Referring toFIGS.1A and1C, the lower bound of the eyeball12is disposed at the peak point32of an arc of concavity32in the lower eyelid14. Referring toFIGS.1B and1C, the upper bound of the eyeball12is disposed at the peak point34of an arc of concavity34in the upper eyelid16.FIG.1Dis a side view illustrating the concavity in the upper and lower eyelid14,16resulting from the bounds of the eyeball12.

As used herein, the “height of the eye HE” refers to the maximum distance between the lower eye region bound66and the upper eye region bound68.

Referring toFIG.2, a nose region36can include a central nose tip38, first and second nostrils40,42, and a columella separating the first and second nostrils40,42. The first and second nostrils40,42are each bounded by an outer nostril wall46,48and internally by the columella. The columella terminates in a base44.

Referring toFIG.3, a mouth region50includes upper and lower lips52,54that are bounded on their outer periphery by the vermillion border56. The vermillion border has an upper most point58in the upper lip52and a lower most point60in the lower lip54. The mouth region50also includes first and second corners62,64of the mouth.

Referring toFIG.14, conventional face masks200are typically flat, two-dimensional masks200with one-size fits all eye openings202and spacing. Such masks200also typically have a one-size fits all opening for the mouth204and nostrils206. When worn, conventional mask200do not align well with eyes, and other features of the human face of many users. With respect to the eye region, such conventional, ill-fitting masks200can cause discomfort by resting on the eye or covering the eye and/or causing ineffective treatment because the opening overlies the under-eye region to be treated rather than the mask surface having the active, cosmetic, and/or therapeutic agent. Similarly, in the mouth region, ill-fitting masks200can either overlap with the lip area or be spaced too far from the lips or nose portions thereof. In the region, ill-fitting masks200can interfere or overlap with the nostrils. The methods in accordance with various embodiments of the disclosure advantageously provide custom-fit openings that can allow the mask200to align properly, for example in the eye region resulting improved comfort and fit.

Referring toFIG.6, in accordance with embodiments, the methods in accordance with embodiments of the disclosure can provide a mask100having an eye opening102that can have a lower peripheral edge, first edge104, that lies close to the inner eyelid liner18of the lower eyelid14of the user, thereby allowing improved coverage of the under-eye region by the mask100portion having an active, cosmetic, and/or therapeutic agent disposed thereon. In accordance with other or further embodiments, the methods in accordance with the disclosure can provide a mask100having a pair of eye openings102that are spaced such that each opening lies at a desired, close, but non-overlapping position from the medial canthus26. In accordance with other or further embodiments, the methods in accordance with the disclosure can provide a mask100having a nose opening114that overlaps partially with the outer nostril walls46,48, but does not interfere with the nostrils40,42or cause discomfort when breathing. In accordance with other or further embodiments, the methods in accordance with the disclosure can provide a mask100having mouth opening124that is spaced close to the vermillion border56of both the upper and lower lips52,54. In accordance with embodiments of the disclosure, masks and methods of making the same can include any combination of custom-defined openings and/or standard-sized (universal fit) openings. For example, a mask can include a custom-defined mouth opening in accordance with embodiments of the disclosure with standard-sized eye openings. For example, a mask can include custom-defined eye opening in accordance with embodiments of the disclosure with standard-sized nose and/or mouth openings. For example, a mask can include a custom-defined nose opening in accordance with embodiments of the disclosure, with no openings for eyes or mouth. For example, the mask can include custom-defined eye, mouth, and nose openings in accordance with embodiments of the disclosure. Any other such combinations of defined openings are contemplated herein.

The methods and masks100in accordance with embodiments of the disclosure provide improved fit and comfort. Improved fit can allow for better contact of the active, cosmetic, and/or therapeutic agents on the mask100with desired regions of the face. Desired regions can include one or more of, for example, the under-eye region, the corners of the nose45just outboard the outer nostril walls46,48, and the skin close to the lips. Improved fit can include masks100that cover such desired regions, while not foregoing coverage of other regions, such as above the eye, and/or without interfering with facial features where coverage is to be avoided, such as the eyeball12, nostril40,42, and/or lips52,54. Mask100in accordance with embodiments of the disclosure can also have improved fit in not only contacting desired regions, but maintaining closer contact without gaps or bubbles in the mask100that would disrupt contact with a desired region.

Referring toFIG.4, in accordance with embodiments of the disclosure, a method of making a mask100for a face includes determining a lower eye region bound66, determining and upper eye region bound68, setting a first anchor point 0 mm to 10 mm below the lower eye region bound66and second anchor point 0 mm to 10 mm above the upper eye region bound68, and defining at least one eye opening102for a face mask100having a first edge that intersects with the first anchor point and the second edge that intersects with the second anchor point. As used herein, an anchor point refers to a digital reference point, which is a fixed point in space and selected on a digital representation of the target area.

In accordance with embodiments of the disclosure, a method of making a mask100for a face includes determining a lower eye region bound66; determining an upper eye region bound68by locating an upper bound of the eyeball12; and defining the at least one eye opening102such that, when the mask100is fitted to the face, the first edge104is disposed 0 mm to about 10 mm below the lower eye region bound66and the second edge106is disposed 0 mm to about 10 mm above the upper eye region bound68. The method can further include creating the face mask100having the at least one eye opening102. The eye openings may be the same, similar, or distinctly different from each other to accommodate a particular individual's two eyes.

In any of the embodiments herein the upper eye region bound68can be one or more of a peak point34of an arc of concavity in an upper eyelid16of the at least one eye when the eye is closed; a peak point in the fold line in the upper eye lid; a highest point of an upper eyelash24when the eye is open; and an edge of the upper eye lid. The highest point of an upper eyelash when the eye is open can be selected in embodiments to be an average highest point among a group or all of the upper eyelashes or alternatively can be the highest point of the longest upper eyelash.

In any of the embodiments herein, the lower eye region bound66can be determined by locating one or more of a position of one or more of a lowest extent of one or more lower eyelashes22of the at least one eye when the eye is open, a lower bound of the eyeball12as determined by a peak point32of an arc of concavity in the lower eyelid14of the at least one eye when the eye is closed, an edge of the eye ball on the lower side, an edge of the lower eye lid, and a lowest extent of one or more upper eyelashes24of the at least one eye when the eye is closed.

In any of the embodiments herein, the creation of the face mask100can include exporting data relating to the defined at least one eye opening102to a cutting tool to define a cutting path for cutting the eye opening102into a mask100substrate. Alternatively, the creation of the face mask100can include combining the digital data relating to the defined at least one eye opening102with digital data associated with the face mask100shape to defined in the digital data of the face masks100the eye opening102, which can be exported for direct printing of the masks100or molds for making masks100having the eye openings102formed therein currently with the mask100formation. Alternately, the data can be transformed or translated to a cutting path or machine path.

In various embodiments, the curvature of the first and second edges104,106of the eye opening102is defined to have a corresponding degree of curvature to the inner lining18,20of the lower and upper eyelid14,16.

In various embodiments, the method includes determining a position of the medial canthus26and a position of the lateral canthus28and setting third and fourth anchor points, respectively, 0 to 10 mm outboard, relative to the eyeball12, from the medial and lateral canthus26,28. In such embodiments, defining the at least one eye opening102can include defining a peripheral curve that intersects at a first edge104through the first, third, and fourth anchor points, and at a second edge106through the second, third, and fourth anchor points. In various embodiments, additional anchor points can be used.

In various embodiments, the method can include or further include determining a position of the medial canthus26and a position of the lateral canthus28and defining the eye opening102such that corners110,112of the eye opening102are spaced about 0 mm to about 10 mm outbound, relative to the eyeball12, from the medial and lateral canthus26,28, respectively. Unless otherwise specific, as used herein, “outboard of the medial canthus26” or “outboard of the lateral canthus28” refers to positioning outboard from the respective canthus relative to the position of the eyeball12. That is, the eyeball12is considered inboard of the respective canthus.

In various embodiments, the method can include obtaining a digital geometric representation of the face of the user.FIG.5illustrates one embodiment of obtaining such a digital representation. Any known methods of obtaining a digital representation of an object, such as a face, or converting images to digital geometric representations can be used. In various embodiments, the method can include one or more of displaying, storing, and transmitting of the digital representation or data associated therewith. Any known processes, storage media, and display systems and equipment can be used.

Referring toFIG.6, in accordance with an embodiment of the disclosure, a mask100can include an eye opening102defined in accordance with embodiments of the method of the disclosure. As illustrated inFIG.6, the mask100can further include a mouth opening124and/or nose opening114as discussed in detail below.

Referring toFIG.7A, a mask100in accordance with various embodiments of the disclosure can have an eye opening102having first and second opposed curve edges104,106with the height HEOextending between the edges104,106. The first edge104can be disposed about 0 mm to about 10 mm below the lower eye region bound66. The second edge106can be disposed about 0 mm to about 10 mm above the upper eye region bound68. The height HEOof the eye opening102can be defined by the maximum distance between the first edge104and the second edge106. In various embodiments, the mask100can have an eye opening102height HEOat least equal to the height of the eye HE.

A mask100in accordance with embodiments of the disclosure can have a first edge104of an eye opening102that is disposed about 0 mm to about 10 mm below a lower eye region bound66when the mask100is worn. In accordance with various embodiments, the eye opening102can include second edge106that is disposed about 0 mm to about 10 mm above the upper eye region10bound68when the mask100is worn.

In various embodiments, the mask100can include or further include an eye opening102having first and second corners (also referred to as side edges)110,112that are spaced from the medial and lateral canthus26,28, respectively, about 0 to about 10 mm outboard, from the medial and lateral canthus26,28. The spacing of the first and second corners110,112from the medial and lateral canthus26,28, respectively, can be the same or different.

In any of the embodiments herein, the mask100or method of making a mask100can include defining the mask100to have first and second eye openings102corresponding to both eyes of the user.

In various embodiments, the mask100or method of making a mask100can include defining a registration feature in the mask100to aid in aligning the mask100when worn. For example, in embodiments, the registration feature can be a portion of the mask100covering one or more of the nose or portion thereof, the chin or portion thereof, and a jaw section. Inclusion of coverage of such portions of the mask100can aid the users in aligning the mask100upon application such that the openings of the mask100properly align with the target region.

In accordance with embodiments, the method can further include determining the relative spacing between the eyes of the users and defining a mask to have a spacing that is within 0 mm to 10 mm of the spacing between the eyes of the user. The spacing between the eyes of a user can be defined as the spacing between the medial canthus26of each eye and the spacing between the eye openings of the mask can be defined between the first corners of each eye opening. In embodiments, the method can further include determining the relative spacing between one or more features to which an opening is to be defined. For example, where a mask100is being created to have an eye opening and a mouth opening, a spacing between a feature of the mouth and a feature of the eye can be determined and the mask can be defined to have a spacing that is about 0 mm to about 10 mm of this spacing, with the mask spacing between defined between features or bounds of the opening disposed adjacent the selected features of the eye and mouth. Such determination of relative spacing of facial features and associated openings can be done with any openings and target areas. For example, relative spacing between nostrils or the base of the columella and the upper lip can be used to define spacing between the upper bound of the mouth opening and lower bound of the nose opening. In some embodiments the pupillary distance (PD) or interpupillary distance (IPD) may be used to determine relative spacing between the eyes.

In any of the embodiments disclosed herein, the mask100can be a two-dimensional mask or a three-dimensional mask. In accordance with embodiments, a two-dimensional mask can be a substrate mask, nonwoven mask, woven mask, knit mask, paper mask, cotton mask, any other type of woven, nonwoven, gel, hydrogel type of mask made of natural or synthetic fibers, composites, gel, hydrogels, films, apertured films or any other such mask making materials as is known in the art. In any of the embodiments disclosed herein, the three-dimensional mask can be a self-supporting mask. As used herein, the term “self-supporting” means that an element of or the applicator in its entirety retains a substantial portion of a defined three-dimensional shape without the aid of external support structures when resting on a horizontal surface in air. In any embodiment, the mask may be a semi-three dimensional mask where cuts, folds, or seams are used in a flat substrate material to create a less flat or more three-dimensional mask. In any of the embodiments disclosed herein, the mask can be a single-dose applicator or for single use having a single dose of the active, cosmetic, and/or therapeutic. As used herein, the term single-dose means an applicator comprising sufficient active agents to afford a user only a single application of the active agent via the applicator. In any of the embodiments disclosed herein, the mask can be for multiple use. For example, active, cosmetic, and/or therapeutic agents can be applied and successively reapplied for multi-use. In any of the embodiments disclosed herein, the mask can be disposable. As used herein, the term disposable refers to applicators intended to be discarded after use rather than durable, or semi-durable implements intended for multiple users either with or without the reapplication of an active agent. In any embodiment, the mask can be a durable item suitable for washing by hand or in a dishwasher or clothing washing machine.

In various embodiments, the lower eye region bound66can be defined at one or more of the lowest one of the lowest extent of one or more lower eyelashes22of the at least one eye when the eye is open, a lower bound of the eyeball12as determined by a peak point32of an arc of concavity in the lower eyelid14of the at least one eye when the eye is closed, and a lowest extent of one or more upper eyelashes24of the at least one eye when the eye is closed. For example, in embodiments, the peak point32of an arc of concavity in the lower eyelid14can be determined manually by rotating a three-dimensional image of the face or eye region thereof and digitally altering the angle of the light to estimate the location of the peak point32of the arc of concavity. In embodiments, for example, the peak point32of the arc of concavity in the lower eyelid14can be determined by taking cross-sections in a three-dimensional image of the face or eye region, perpendicular to the direction of the curvature that is vertically from the forehead to chin and observing the lowest point in the cross-section. The cross-sections can be taken at one or more reference points in the eye region to define points which are then connected to form the arc of concavity defining the eye boundary. In yet other embodiments, an algorithm, such as a machine learning algorithm, neural net, or deep learning algorithm can be used to teach a software tool to identify the peak point32of an arc of concavity on a digital representation of the face or at least the eye region thereof.

For any of the reference points or anchor points disclosed these may be identified manually or through a machine learning algorithm, image analysis, or other approach, for example facial landmark detection such as Dlib (available from github). Reference points or anchor points may be determined in part through an app and or by a user. Pixels in a 2D image or 3D information may be used to select the anchor points through edge finding algorithms, feature extraction, using texture, color, RBG or grayscale values, shadows, or other features from a 2D image or 3D surface. In various embodiments, the lower eye region bound66is the lowest one of the lowest extent of one or more lower eyelashes22of the at least one eye when the eye is open. In some embodiments, the lower eye region66bound is the lower bound of the eyeball12as determined by a peak point32of an arc of concavity in the lower eyelid14of the at least one eye when the eye is closed. In some embodiments, the lower eye bound is the upper most one of the lowest extent of one or more lower eyelashes22of the at least one eye when the eye is open.

In various embodiments, the lower eye region bound66is the lowest extent of one or more lower eyelashes22of the at least one eye when the eye is open. For example, the lower eye region bound66can be the lowest extent of the longest one of the lower eyelashes22of the at least one eye. Alternatively, the lower eye region bound66can be defined at an average of the lowest extents of each of the lower eyelashes22.

FIGS.7A and7Billustrate an embodiment of the mask100and method of the disclosure in which the lower eye region bound66is selected to be the peak point32of an arc of concavity in the lower eyelid14of the at least one eye when the eye is closed.FIG.8illustrates an embodiment of the mask100and method of the disclosure in which the lower eye region bound66is selected to be the lowest extent of one or more lower eyelashes22when the eye is open.

In various embodiments, the eye opening102of the mask100has or is defined to have a first edge104that is arranged to contact or have a defined spacing from the lower eye region bound66when the mask100is worn. The first edge104of the eye opening102can be positioned from about 0 mm to about 10 mm below the lower eye region bound66. For example, the first edge104of the eye opening102can about 0 mm to about 10 mm, about 1 mm to about 4 mm, about 0 mm to about 5 mm, about 2 mm to about 6 mm, about 1 mm to about 8 mm, and about 5 mm to about 10 mm. In various embodiments, the first edge of the eye opening102can be about 0, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, or 10 mm below the lower eye region bound66. In various embodiments, the lowest point of the first edge104of the eye opening102, farthest from the lower eye region bound66can be used as the reference point for measuring the distance between the lower eye region bound66and the first edge104of the eye opening102.

Positioning of the first edge104of the eye opening102about 0 to 10 mm from the lower eye region bound66can advantageously provide an eye opening102that has tight fit to the eye, allowing maximum coverage of the under-eye region, without causing discomfort by interfering with the lower eyelashes22or overlapping too closely with the edge of the lower eyelid14.

In embodiments, the upper eye region bound68can be determined by locating an upper bound of the eyeball12as determined by a peak point34of an arc of concavity in an upper eyelid of the at least one eye when the eye is closed. The mask100can have an eye opening102that is positioned when worn such that the second edge106is at or above the upper eye region bound68. Eye openings102positioned at or above the peak point34of an arc of concavity in the upper eyelid have been found to have improved comfort to the user, as the mask100does not rest on the upper eyelid16in such a way to interfere with movement of the eyelid or eyeball12.

In various embodiments, the second edge106can also or alternatively be spaced to be at or above the highest extent of the upper eyelashes24when the eye is open. In various embodiments, the highest extent of the upper eyelashes24can be the highest extent of the longest one of the upper eyelashes24of the at least one eye. Alternatively, the highest extent of the upper eyelashes24can be the average of the highest extents of each of the upper eyelashes24.

The second edge106of the eye opening102, can be positioned from about 0 mm to about 10 mm above the upper eye region10bound. For example, the second edge of the eye opening102can about 0 mm to about 10 mm, about 1 mm to about 4 mm, about 0 mm to about 5 mm, about 2 mm to about 6 mm, about 1 mm to about 8 mm, and about 5 mm to about 10 mm, above the upper eye region10bound. In various embodiments, the first edge of the eye opening102can be about 0, 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, or 10 mm above the upper eye region10bound. In various embodiments, the highest point of the second edge of the eye opening102, farthest from the upper eye region10bound can be used as the reference point for measuring the distance between the eye region10bound and the second edge of the eye opening102.

FIGS.7A and7Billustrate an embodiment in which the second edge106is disposed within 0-10 mm the peak point34of an arch of concavity in the upper eyelid16.FIGS.8A and8Billustrate an embodiment in which the second edge106is spaced a distance above the peak point34of an arc of concavity in the upper eyelid16and at the highest extent of the upper eyelashes24.FIGS.9A and9B and10A and10Billustrate an embodiment in which the second edge106is spaced from the upper eye region bound68a distance of about 2 to about 4 mmFIGS.11A and11Billustrate an embodiment in which the second edge106is disposed near an edge of the eye socket.

In accordance with embodiments of the disclosure, the method can include obtaining one or more digital geometric representations of at least one eye region10of the user's faces. The digital geometric representations can include variations in which the user's eye is open and the user's eye is closed. The digital geometric representation can include images or scans representing front profiles and/or side profiles of the user. In various embodiments, the digital geometric representation can be of the entire user's face or of the entire eye region10, including both eyes or any portion of the user's face including at least one eye region10.

The digital geometric representation can be obtained, for example, by any one or more of 3D scanners, 2D scanners, cameras, smartphone camera, digital applications for tablets and phones, and other known equipment for obtaining digital geometric data. An Artec Spider, available from Artec Group Palo Alto, CA is an example of a suitable 3D scanner. An example mobile application for a cellular phone or table is 123D Catch from Autodesk or Capture: 3D Scan Anything” by developer, Standard Cyborg or Bellus3D FaceApp by Bellus3D Inc. or the TrueDepth camera system form Apple.

The digital geometric representation of the human face or portion thereof can be used as a whole or partitioned with only a portion of the total representation being used. Furthermore, portions of the geometry derived from the scan or other imaging technique can be removed or edited from the digital geometric representation. The digital geometric representation data may be used without alteration, or the geometry of the representation may be altered. For example, digital processing may be used to alter the digital data. For example, the digital data can be altered to be provided as a mesh to allow for measurement of various features on the digital data. For example, a two dimensional set of data from an image or scan can be altered to provide a three-dimension representation of the two-dimensional data.

In any of the embodiments of the disclosure, any one or more of the various digital processing equipment, digital geometric representations, graphics programs, and graphical displays may be stored in a tangible computer readable memory or medium and/or shared or cloud-based medium, and execute one or more processors to perform the functions described herein. For example, in embodiments, the digital geometric representation can be obtained by a user using a smartphone camera and/or mobile application and subsequently uploaded to a manufacturer's shared memory or medium for manufacturing of the mask100. In other embodiments, digital geometric representations can be obtained with scanners or other imaging devices located at the point of sale of the mask100. The data from the digital geometric representations can be stored locally or on a shared medium.

In various embodiments, the lower and upper eye region bounds66,68are defined using the digital geometric representation. Various graphics programs can be used for obtaining measurements and manipulations of the data of digital geometric representation. For example, Blender, by Blender Foundation can be used to view, manipulate, and/or modify the digital geometric representation data. In various embodiments, the digital geometric representations can be used to define anchor points corresponding to the lower and upper eye region bounds66,68. The methods in accordance with embodiments of the disclosure include defining at least two anchor points for an eye opening102. In some embodiments, the method can include defining more than two anchor points. For example, in embodiments, the method can include defining four anchor points corresponding to the upper eye region bound68, lower eye region bound66, medial canthus26, and lateral canthus28. Any suitable number of anchor points can be defined.

In various embodiments, the anchor points are used to define the peripheral edges of the eye opening102. As described herein, the anchor points can be set at or offset a distance from the respective target feature of the eye. For example, an anchor point can be about 0 mm to about 10 mm below an anchor point corresponding to the lower eye region bound66. For example, an anchor point can be about 0 mm to about 10 mm above an anchor point corresponding to the upper eye region bound68. In any of the embodiments, an anchor point can be off-set about 0 mm to about 10 mm from the respective target feature of the eye region.

Once the at least two anchor points are defined, the method can include fitting one or more curves to the anchor points. For example, a Bezier curve can be used to fit curves corresponding to the peripheral edges of the eye opening102to the at least two anchor points. In any embodiments disclosed herein one or more of the following can be used to connect or touch anchor points for defining an opening: Bezier curves, linear segments, parabolas, concave curves, regular or irregular curves, and polygons. In various embodiments, the connector, which defines the edge of the opening can be curved or can have any of the shapes described above. In various embodiments, the connector can mimic, follow, or parallel in whole or in part curvatures and pathways of the underlying physiology of a feature in the target region. For example, the connector can mimic, follow, or parallel the curvature of an eye brow, and eye fold, or an eye shape. Such mimicking, following, or paralleling can aid in conforming the opening to a particular user's face functionally and can provide a more aesthetically pleasing wear experience. In other embodiments, a curve can be defined on the digital geometric data from the curvature of the lining of the upper and lower eyelid and digitally shifted to intersect with the anchor point. Other methods of fitting curves to points can be used as is known in the art. In embodiments using a Bezier curve, a curve can be digitally overlaid over the digital representation in the eye region10and handles of anchor points can be adjusted in succession until the curve follows the points of lowest curvature tracing the underlying eyeball12and intersect the anchor points.

Once the curve of the eye opening102is defined digitally, the data can be exported in any suitable file format to be used in creating the mask100. For example, the curve can be converted to a mesh using a series of segments that allows for export to cutting tools or other digital tool for printing the mask100or defining a mold for making the mask100. For example, the data of the curve can be converted to mesh and exported as a DXF file. When converting the curve defining the eye opening102into a mesh, about 30 to about 100 segments can be used. For example, a mesh can be generated using about 30 to about 100 segments, about 50 to about 100 segments, about 30 to about 60 segments, about 40 to about 80 segments, or about 70 to about 90 segments. Other suitable numbers of segments include about 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, and 100 segments. In some embodiments, the digital mesh of the curve defining the eye opening102is exported to a digital cutting tool and used as a cutting path for cutting an eye opening102in a mask100material.

In other embodiments, the mesh of the curve can be used in generated a digital geometric representation of the mask100to be created with eye openings102rather than have the eye openings102subsequently cut out after mask100formation, formation may be accomplished by any method, including but not limited to, thermoforming, hydroforming, hydraulic forming, and vacuum forming. In embodiments, the eye openings can be cut by any method, including but not limited to: laser cutting, water jet cutting, hand cutting, die cutting, hot air cutting—as described in United States Patent Application Publication No. 2017/0354805, incorporated herein by reference. For example, digital printing devices of methods of creating mask100materials using various technologies, such as SLS, SLA, FDM, CLIP, and other additive manufacturing technologies that are known in the art could be used. The mesh of the curve of the defined eye opening102can be incorporated into a mesh of the mask100to digitally eliminate mask100material in the eye opening102, thereby defining the mask100having pre-formed eye openings102. In an embodiment, the mesh of the curve of the eye opening102can be digitally placed over the eye of a face mesh defining the mask100region and extruded in the negative Z direction to intersect and pass through the face mesh. The intersection area of the face mesh inbound of the curve is selectively removed to define the opening. Digital removal of a portion of a mesh can be achieved, for example, using a Boolean difference. The data associated with the mask100having the digitally removed region to define the custom eye openings102can then be exported to suitable printing or manufacturing equipment for formation of the mask100itself.

In accordance with various embodiments, methods of making a mask100can include or further include defining one or more of a nose opening114and a mouth opening124in the mask100.

In accordance with various embodiments, the mask100can include or further include a nose opening114. The nose opening114can be defined, for example to allow the user to breath comfortably while the mask100is worn, while maintaining close coverage of the nose region36and particular the outer corners of the nose45. Referring toFIG.12, the nose opening114can have a height HNOextending between first and second edges116,118, and a width WNOextending between third and fourth edges120,122. In various embodiments, the mask100can have a nose opening114such that the third and fourth edges116,118at least partially overlap with the outer nostril wall46,48. For example, the third and fourth edges116,118can be disposed on the outer nostril wall46,48, spaced about 0 mm to about 10 mm from the outermost edge43of the respective nostril40,42. For example, the spacing can be about 0 mm to about 10 mm, about 0 mm to about 5 mm, about 2 mm to about 6 mm, about 1 mm to about 5 mm, about 3 mm to about 5 mm Other suitable spacings can include, for example, about 0, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, and 10 mm. The spacing of the third or fourth edges from the outermost edge43of the nostril can be the same or different. In various embodiments, the nose opening114can have a first edge that is spaced about 0 mm to about 10 mm from the base of the columella44. In various embodiments, the nose opening114can have a second edge that is disposed on a portion of the tip38of the nose. For example, the second edge118can be arranged such that is extends across the top of the first and second nostrils40,42, and in the area of the nostril is spaced about 0 to about 10 mm from the upper most point49of the respective nostril40,42. For example, the spacing can be about 0 mm to about 10 mm, about 0 mm to about 5 mm, about 2 mm to about 6 mm, about 1 mm to about 5 mm, about 3 mm to about 5 mm Other suitable spacings can include, for example, about 0, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, and 10 mm. The spacing of the second edge118from the first and second nostrils40,42can be the same in the region of each nostril or different in the region of each nostril.

In embodiments, a nose opening114can be defined by determining a position of an outermost edge43of each of first and second nostrils40,42, setting a first nose anchor point about 0 mm to about 10 mm from the outermost edge43of the first nostril40, setting a second nose anchor point about 0 mm to about 10 mm from the outermost edge43of the second nostril42, and defining a nose opening114having side edges120,122that intersect with the first and second nose anchor points. In various embodiments, the method can include or further includes determining a position of the base of the columella44, determining a position of the tip38of the nose, setting a third nose anchor point about 0 mm to about 10 mm from the position of the base of the columella44and a fourth nose anchor point 0 mm to about 10 mm from the position of the tip38of the nose, and defining a nose opening114to have a circumferential edges that intersects with each of the first, second, third, and fourth anchor points. In various embodiments, the method can include or further includes determining an uppermost point49of at least one of the first and second nostrils40,42; setting a fifth anchor point about 0 to about 10 mm from one of the uppermost points of the first and second nostrils40,42, and defining the mask100to have a nose opening114with top and bottom edges116,118that intersect with the third and fifth anchor points, respectively. In various embodiments, the fifth anchor point can be the uppermost one of the uppermost point49of the first and second nostrils40,42. In various embodiments, the fifth anchor point can be the uppermost point of the first nostril40and a fifth anchor point can be defined at the upper most point of the second nostril42. In various embodiments, the method can include determining the uppermost point of each of the first and second nostrils40,42and defining fifth and sixth anchor points at each of the uppermost points and defining a nose opening114having a second edge that intersects with the first, second, fifth, and sixth nose anchor points. Optionally, the second edge118in such embodiments can intersect with the fourth nose anchor point. In various embodiments, the nose opening114can be defined such that the edges of the opening114interest with two anchor points, three anchor points, four anchor points, five anchor points, six anchor points, or more. Further, the nose hole may be a single nose opening, one opening per nostril, or may be a series of holes or other treatments to enable air permeability in the defined region of the nose to allow the user to breathe comfortably while wearing the mask.

In accordance with various embodiments, the mask100can include or further include a mouth opening124. The mouth opening124can be, for example, defined to allow for close coverage of the mouth region50without interfering with movement of the lips52,54and/or overlapping or covering the lips52,54. Referring toFIG.13, the mouth opening124can have a height HMO extending between first and second edges126,128, and a width WMOextending between first and second corners130,132. In various embodiments, the mask100can have a mouth opening124defined such that the first edge126is spaced about 0 mm to about 10 mm from the lower point60of the vermillion border56on the lower lip54. For example, the spacing can be about 0 mm to about 10 mm, about 0 mm to about 5 mm, about 2 mm to about 6 mm, about 1 mm to about 5 mm, about 3 mm to about 5 mm Other suitable spacings can include, for example, about 0, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, and 10 mm. In various embodiments the mask100can have a mouth opening124defined such that the second edge128is spaced about 0 mm to about 10 mm from the upper point58of the vermillion border56on the upper lip52. For example, the spacing can be about 0 mm to about 10 mm, about 0 mm to about 5 mm, about 2 mm to about 6 mm, about 1 mm to about 5 mm, about 3 mm to about 5 mm Other suitable spacings can include, for example, about 0, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, and 10 mm. In various embodiments, the mask100can have a mouth opening124defined such that the first and second corners130,132(also referred to as first and second edges or sides) are spaced about 0 mm to about 10 mm from the first and second corners62,64of the mouth62,64. For example, the spacing can be about 0 mm to about 10 mm, about 0 mm to about 5 mm, about 2 mm to about 6 mm, about 1 mm to about 5 mm, about 3 mm to about 5 mm. Other suitable spacings can include, for example, about 0, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, and 10 mm. The spacing of the first and second corners130,132of the mouth opening124can have the same spacing from the respective corner62,64of the mouth or can have different spacing.

In accordance with various embodiments, the methods of making a mask100can include or further include defining a mouth opening124by determining a position of an upper point58of the vermillion border56; determining a position of a lower point60of the vermillion border56, setting a first lip anchor point about 0 mm to about 10 mm from the upper point58of the vermillion border56, setting a second lip anchor point about 0 mm to about 10 mm from the lower point60of the vermillion border56, and defining a mask100having a mouth opening124with a first edge126that intersects with the first lip anchor point and a second edge128that intersects with the second lip anchor point. A mouth can include two upper points58of the vermillion border56as illustrated inFIG.13. In embodiments, the method can include determining a position of each of the upper points58and two first lip anchor points can be set at about 0 m to about 10 mm from each of the upper points58of the vermillion border. The spacing of the first anchor points can be the same or can be different. In other embodiments, the method can include determining a position of the upper most one of the upper points58. In various embodiments, the method can include or further include determining position of each of the first and second corners62,64of the mouth, setting a third lip anchor point about 0 mm to about 10 mm from the first corner62, setting a fourth lip anchor point about 0 mm to about 10 mm from the second corner64, and defining a mouth opening124having a first edge that intersects the first, third, and fourth anchor points, and a second edge that intersects the second, third, and fourth anchor points.

In any of the embodiments of a method of the disclosure defining a nose opening114and/or a mouth opening124, a Bezier curve or any other connector can be used as described above with respect to the eye opening102.

In accordance with any of the embodiments of the disclosure, the mask100can be two-dimensional mask100, or can be three-dimensional masks100. Mask100can be made using any suitable technique in which the openings features as defined by the methods disclosed herein can be incorporated. For example, the methods in accordance with embodiments of the disclosure can be used to define cutting paths for cutting openings into preformed mask100materials or into flat mask materials such as substrate masks. In accordance with embodiments, laser cutting can be used for cutting the defined cutting paths. Additionally or alternative, in embodiments, custom-defined molds may be used to define a gel mask having one or more openings in accordance with embodiments of the disclosure. For example, the methods in accordance with embodiments of the disclosure can be used to define an opening region in a digital geometric representation of a three-dimensional mask100to be created by digital printing or other molding techniques. For example, mask100can be digitally created using techniques such as described in any one or more of U.S. Patent Application Publication Nos. 2017/008566, 2017/0354805, and 2017/0354806, the respective disclosures of which are incorporated herein by reference. The process to define one or more openings may be manual or partial or fully automated and may use various algorithms. Further, perspective angle of the image may be accounted for and or measured to ensure data quality. Perspective angle corrections may use comparisons of multiple images, phone sensor data, by guiding a user during acquiring images and any digital data, or other means.

Masks100having openings made in accordance with the methods of embodiments of the disclosure can include any suitable active, cosmetic, or therapeutic agent to be applied to the face of the user. For example, active, therapeutic, and/or cosmetic agents can include active ingredients, carriers, chassis, emulsions, hydrogels, adhesives, process aides (such as thickeners, rheology modifiers, etc.). Active agents may further comprise a release layer to help active agents transfer from the applicator to the target surface. Active agents may include adhesive materials, active chemical agents, absorbent materials such as absorbent gel materials or absorbent foam materials placed according to either the diagnostic scan or relative to identifiable features. As an example, it may be desirable to dispose an absorbent foam material along cheekbones, brow or nose of a scanned user's facial mask100, the disposition sites may be determined according to the geometry of the representation rather than according to the diagnostic scan of the user. Active agents may be in one or more physical forms, including but not limited to: foams, liquids, powders, films, fibers, creams, gels, hydrogels, encapsulated active agents, solids, combinations of these forms and other forms. Some examples of active agents include but are not limited to: moisturizer, anti-aging, anti-wrinkle, skin tone control, anti-irritation, sensates (e.g. menthol), heating or cooling chemistries, skin tightening, hair removal, hair regrowth, fungicide, antibacterial, antiviral, surfactants, cleaning agents, copper ion eluting (such as from Cupron of Richmond, Va.), antioxidants, vitamins, sunscreen, rejuvenation agents, wound healing agents, sebum management agents, astringents, exfoliates, anti-inflammatory, leave on, overnight, dry skin, itchy skin, cracked skin, peptides, acne, scar treatments, sore muscles treatments, medicaments including pharmacological actives to treat disease states or other acute or chronic issues such as eczema, rashes, acne, cancer, cold sore, Psoriasis, Rosacea, Vitiligo, warts, Herpes, fungal infection, Actinic Keratosis, ulcers, shingles, poison ivy, and insect bites. Further, the medicaments, including pharmacological actives, can go beyond topical effect and be designed for transdermal delivery of an active into the bloodstream or other internal tissue. Examples of therapies, both prescribed and un-prescribed include: nicotine, Botox, and hormone supplements.

In one embodiment, the inclusion of one or more scents, perfume or fragrance compositions may be applied to the mask100for subsequent deposition to the face. However, a portion, or all, of the included one or more scents, perfume or fragrance compositions may act as experience agents. The experience agent provides a smell in the environs of the mask100when in use. For example, the smell provided by a fragrance to suggest outdoor flower garden aroma may be desirable when applying cosmetic agents to the face of a consumer/wearer. Experiential agents need not necessarily be located on the target structure contact surface of the mask100. The agents may be located in a region not in contact with the target structure, such as on a non-contacting portion of the application side of the applicator or anywhere on any applicator side that is non-contacting to the target structure. The experience agent may be selected to accompany a selected appearance feature.

EXAMPLES

An eye opening102cutting path was created digital using a method in accordance with the disclosure.FIGS.7A and7Billustrate the mask100formed from the developed custom eye opening102.

Digital data corresponding to a three-dimensional mesh of a face was loaded into Blender graphics program. The mesh of the face was aligned flat, with the nose pointing up in the positive Z direction, the chin and forehead at approximately the same Z height, and the left and right cheeks at approximately the same Z height. The face mesh was oriented to a top down orthographic view. The face mesh was viewed with and without captured texture/color information to provide complementary information on where the reference points are located.

Four anchor points were selected on the digital geometric representation of the face presented as a mesh. The lower eye region bound66was defined at the lowest extent of the upper eyelashes24when the eye is closed. A first anchor point104was set to be about 3.5 mm below the lower eye region bound66. The upper eye region bound68was defined at the peak point34of an arc of concavity of the upper eyelid16. A second anchor point106was set to be about 3.5 mm above the upper eye region bound68. The position of the medial and lateral canthus26,28was determined on the mesh and third and fourth anchor points110,112were set to be about 3.5 mm outbound (relative to the eyeball12) from the medial and lateral canthus26,28, respectively. The mesh was manipulated at various angles in the software to help define the anchor points.

A Bezier curve was overlaid over the digital geometric representation 2 cm floating above the digital geometric representation of the eye with the four anchor points. The handles for each of the anchor points was adjusted in succession until the Bezier curve followed the points of lowest curvature tracing the underlying eyeball12. Once achieved, the Bezier curve defined the eye opening102.

The Bezier curve converted to a mesh and exported as a DXF file to be used in an XY laser cutter. The mesh of the Bezier curves as generated to have approximately 50 segments. The eye openings102were then cut using the laser cutter into an already formed mask, thereby forming the eye openings102shown inFIGS.7A and7B.

A face mesh having eye-openings102defined therein in accordance with a method of the disclosure was generated for direct printing of the face mask having the eye openings formed upon printing.

Digital data corresponding to a three-dimensional mesh of a face was loaded into Blender graphics program. The mesh of the face was aligned flat, with the nose pointing up in the positive Z direction, the chin and forehead at approximately the same Z height, and the left and right cheeks at approximately the same Z height. The face mesh was oriented to a top down orthographic view. The face mesh was viewed with and without captured texture/color information to provide complementary information on where the reference points are located.

Four anchor points were selected on the digital geometric representation of the face presented as a mesh. The lower eye region bound66was defined at the lowest extent of the upper eyelashes24when the eye is closed. A first anchor point104was set to be about 3.5 mm below the lower eye region bound66. The upper eye region bound68was defined at the peak point34of an arc of concavity of the upper eyelid16. A second anchor point106was set to be about 3.5 mm above the upper eye region bound68. The position of the medial and lateral canthus26,28was determined on the mesh and third and fourth anchor points110,112set to be about 3.5 mm outbound (relative to the eyeball12) from the medial and lateral canthus26,28, respectively. The mesh was manipulated at various angles in the software to help define the anchor points.

A Bezier curve was overlaid over the digital geometric representation 2 cm floating above the digital geometric representation of the eye with the four anchor points. The handles for each of the anchor points were adjusted in succession until the Bezier curve followed the points of lowest curvature tracing the underlying eyeball12. Once achieved, the Bezier curve defined the eye opening102.

The Bezier curved was then used to create an eye opening102in a face mesh digitally and subsequently direct print a mask with the defined eye openings removed upon printing. The Bezier curve was converted into a mesh with approximately 50 segments and extruded in the negative Z direction to the extent that it intersects and passes through the face mesh surface. In particular, the Bezier curve was originally 20 mm above the eye of the face mesh and extruded −50 mm to intersect the face mesh. The face mesh is then selected and a Boolean difference with the extruded mesh eye opening cut path was used to remove the eye region within the cut path to leave the defined eye opening in the face mesh. The resulting face mesh having the eye openings removed therefrom can then be exported for direct printing.

A nose opening114cutting path was created digitally using a method in accordance with the disclosure.FIG.12illustrates the mask100formed from the developed custom nose opening114.

Digital data corresponding to a three-dimensional mesh of a face was loaded into Blender graphics program. The mesh of the face was aligned flat, with the nose pointing up in the positive Z direction, the chin and forehead at approximately the same Z height, and the left and right cheeks at approximately the same Z height. The face mesh was oriented to a top down orthographic view. The face mesh was viewed with and without captured texture/color information to provide complementary information on where the reference points are located.

Four anchor points were selected on the digital geometric representation of the face presented as a mesh. Left and right anchor points120and122are set as the midpoint of the outer nostril walls on either side46and48. Upper anchor point118is set as the center of the nose above the columella, 3 mm above the highest point of the nostril49. Lower anchor point116is set as the center of the nose below the columella, 3 mm below the base of the columella44. The mesh was manipulated at various angles in the software to help define the anchor points.

A Bezier curve was overlaid over the digital geometric representation 2 cm floating above the digital geometric representation of the nose with the four anchor points. The handles for each of the anchor points were adjusted in succession until the Bezier curve followed the central line of the nostril sidewalls46,48. Once achieved, the Bezier curve defined the nose opening114.

The Bezier curve converted to a mesh and exported as a DXF file to be used in an XY laser cutter. The mesh of the Bezier curves as generated to have approximately 50 segments. The nose opening114was then cut using the laser cutter into a mask material, thereby forming the nose opening114shown inFIG.12.

A face mesh having a nose opening114defined therein in accordance with a method of the disclosure was generated for direct printing of the face mask having the nose openings formed upon printing.

Digital data corresponding to a three-dimensional mesh of a face was loaded into Blender graphics program. The mesh of the face was aligned flat, with the nose pointing up in the positive Z direction, the chin and forehead at approximately the same Z height, and the left and right cheeks at approximately the same Z height. The face mesh was oriented to a top down orthographic view. The face mesh was viewed with and without captured texture/color information to provide complementary information on where the reference points are located.

Four anchor points were selected on the digital geometric representation of the face presented as a mesh. Left and right anchor points120and122are set as the midpoint of the outer nostril walls on either side46and48. Upper anchor point118is set as the center of the nose above the columella, 3 mm above the highest point of the nostril49. Lower anchor point116is set as the center of the nose below the columella, 3 mm below the base of the columella44. The mesh was manipulated at various angles in the software to help define the anchor points.

A Bezier curve was overlaid over the digital geometric representation 2 cm floating above the digital geometric representation of the nose with the four anchor points. The handles for each of the anchor points were adjusted in succession until the Bezier curve followed the central line of the nostril sidewalls46,48. Once achieved, the Bezier curve defined the nose opening114.

The Bezier curved was then used to create a nose opening114in a face mesh digitally and subsequently direct print a mask with the defined nose opening removed upon printing. The Bezier curve was converted into a mesh with approximately 50 segments and extruded in the negative Z direction to the extent that it intersects and passes through the face mesh surface. In particular, the Bezier curve was originally 20 mm above the nose of the face mesh and extruded −50 mm to intersect the face mesh. The face mesh is then selected and a Boolean difference with the extruded mesh nose opening cut path was used to remove the nose region within the cut path to leave the defined nose opening in the face mesh. The resulting face mesh having the nose opening removed therefrom can then be exported for direct printing.

A mouth opening124cutting path was created digitally using a method in accordance with the disclosure.FIG.13illustrates the mask100formed from the developed custom mouth opening124.

Digital data corresponding to a three-dimensional mesh of a face was loaded into Blender graphics program. The mesh of the face was aligned flat, with the mouth pointing up in the positive Z direction, the chin and forehead at approximately the same Z height, and the left and right cheeks at approximately the same Z height. The face mesh was oriented to a top down orthographic view. The face mesh was viewed with and without captured texture/color information to provide complementary information on where the reference points are located.

Four anchor points were selected on the digital geometric representation of the face presented as a mesh. Left and right anchor points130and132are set as 3 mm out from the corners of the mouth62and64. Upper anchor point128is set as 3 mm above the upper vermillion border58in the center of the mouth. Lower anchor point126is set as 3 mm below the lower vermillion border60in the center of the mouth. The mesh was manipulated at various angles in the software to help define the anchor points.

A Bezier curve was overlaid over the digital geometric representation 2 cm floating above the digital geometric representation of the mouth with the four anchor points. The handles for each of the anchor points was adjusted in succession until the Bezier curve generally followed vermillion border at an offset of at least 3 mm Once achieved, the Bezier curve defined the mouth opening124.

The Bezier curve converted to a mesh and exported as a DXF file to be used in an XY laser cutter. The mesh of the Bezier curves as generated to have approximately 50 segments. The mouth opening124was then cut using the laser cutter into a mask material, thereby forming the mouth opening124shown inFIG.13.

A face mesh having a mouth opening124defined therein in accordance with a method of the disclosure was generated for direct printing of the face mask having the mouth openings formed upon printing.

Digital data corresponding to a three-dimensional mesh of a face was loaded into Blender graphics program. The mesh of the face was aligned flat, with the mouth pointing up in the positive Z direction, the chin and forehead at approximately the same Z height, and the left and right cheeks at approximately the same Z height. The face mesh was oriented to a top down orthographic view. The face mesh was viewed with and without captured texture/color information to provide complementary information on where the reference points are located.

Four anchor points were selected on the digital geometric representation of the face presented as a mesh. Left and right anchor points130and132are set as 3 mm out from the corners of the mouth62and64. Upper anchor point128is set as 3 mm above the upper vermillion border58in the center of the mouth. Lower anchor point126is set as 3 mm below the lower vermillion border60in the center of the mouth. The mesh was manipulated at various angles in the software to help define the anchor points.

A Bezier curve was overlaid over the digital geometric representation 2 cm floating above the digital geometric representation of the mouth with the four anchor points. The handles for each of the anchor points was adjusted in succession until the Bezier curve generally followed vermillion border at an offset of at least 3 mm. Once achieved, the Bezier curve defined the mouth opening124.

The Bezier curved was then used to create a mouth opening124in a face mesh digitally and subsequently direct print a mask with the defined mouth opening removed upon printing. The Bezier curve was converted into a mesh with approximately 50 segments and extruded in the negative Z direction to the extent that it intersects and passes through the face mesh surface. In particular, the Bezier curve was originally 20 mm above the mouth of the face mesh and extruded −50 mm to intersect the face mesh. The face mesh is then selected and a Boolean difference with the extruded mesh mouth opening cut path was used to remove the mouth region within the cut path to leave the defined mouth opening in the face mesh. The resulting face mesh having the mouth opening removed therefrom can then be exported for direct printing.