A Solution
for Sleep
Disorders:Case Study

DQBD and GEMTEC’s
Somnosync Sleep Mask
Featuring H350™ 3D
Printed Parts

We chose the H350
3D printer to print thesnap-fit pieces basedon SAF™ technology’s
accuracy and repeatability.
Sebastian Hess

DQBD CEO and Founder2

The universal thing we all do,for eight hours a night if we’relucky, is sleep. Unfortunately,
sleep doesn’t come easy tosome people, and they may
struggle with falling asleep,staying asleep, or from REM
sleep behavior disorders.

The Challenge
To help identify these issues and treat the sourceof the problem, sleep is typically analyzed in asleep laboratory using polysomnography. This
involves extensive and complicated cabling as wellas adhesive electrodes which are connected tothe patient’s skin. The electrodes may cause skinirritation and the quality of sleep can be negatively
affected by the overall experience.

The Solution

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Case
StudyTitle Here2

GEMTEC, through a BMWi funded project incollaboration with the FZI Karlsruhe, developed newtechnology which is accessible for everyone anduser-friendly. To create this low-volume sleep mask,innovator Gerhart Schroff from GEMTEC partneredwith DQBD, an innovation driven design anddevelopment firm based in Germany. DQBD has
extensive additive manufacturing experience in thedesign development process for creating mockups,
prototypes for testing, and initiating new products.
This led DQBD to embed the entire technology intoa convenient, ergonomic, and volume-optimized
housing, utilizing the H350 3D printer powered bySAF technology to print the snap-fit receptacles.

3Science Behind the Somnosync
The Somnosync sleep mask offers contactless detection which identifies REM phases in real-time. This
enables the mask to be utilized in narcolepsy and sleep disorder therapy. The mask features highly
sensitive sensors which register electrical fields generated by rapid eye movement, or REM. Oncepatients are in the beginning of this stage, visual or auditory signals are used to gently wake the user.
This provides access to lucid dreaming which may help change the course of nightmares and allow
the sleeping person to be more in control. The sensor technology works wirelessly, and data can betransmitted via Bluetooth.
Improving REM sleep is critical since, according to neurological sleep research, the risk of developing
dementia or Parkinson ‘s disease is considerably increased in people with REM sleep behavior disorder.

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CaseStudyTitle Here3

4The Somnosync’s Design
The main design challenge was to create wearable housing,which is non-invasive, minimalistic, and comfortable enoughfor sleep. The Somnosync includes a slim design whichhugs the eye area and remains in place throughout sleep
phases, guaranteeing accurate results. DQBD focused on fivestrategic points on the face (without significant anatomicaldifferences) to ensure comfort: the nose hump, pads above
the two eyebrows, and pads at the two temple areas. The
adaptive nose pad on the nose’s hump is cushioned and canbe personalized and replaced by using additive manufacturing
based on a scan.

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CaseStudyTitle Here4

The base housing element is partially decoupled, offering
flexibility at the temple areas. The base housing and temples area single part, so the base is designed in a way which allows thetemples to have enough flexibility to adapt to the head and facecontour. This prevents pressure points from arising. The device
only involves a few parts which can be interchanged, ensuring
efficiency and ease of use. Air circulation was also vital to thedesign since the mask must prevent water condensation due topatients sweating during sleep.
For their design of the Somnosync sleep mask, DQBD won theFOCUS OPEN 2023 Silver Award in June 2023, presented by
the Design Center Baden-Württemberg.

5Additively Manufactured Parts with the H350
The housing components include snap-fit
receptacles for the PCB, battery, and sensors.
Based on the part’s complexity, this would
require an extremely high investment for one ormore injection molds to accomplish theoptimized design that SAF delivers in a single
part. Additionally, printing according to thespecific anatomy of the user’s face is also adetermining factor. This can be completed withadditive manufacturing at a lower cost point
than injection molding.
“We chose the H350 3D printer to print thesnap-fit pieces based on SAF technology’s
accuracy and repeatability. It was essential toprecisely reproduce each snap-fit so theSomnosync’s components remain intact, andthe user’s sleep can be tracked correctly” Sebastian Hess, DQBD CEO and Founder.
Additionally, with the H350’s optimized nesting
capability, more components can fit in a single
build, thus reducing overall cost.
The H350 additive manufactured parts include
multiple clip-on elements (such as the 3+3sensor caps), the battery housing cover, thePCB clip-on, and the connection between thetwo main housings (base and outer housingelement).
Since the design of the snap-fit receptacles is
saved within the GrabCAD Print Pro™ software,
printing can be completed at different locations,achieving the same result in terms of precisionand functionality.
Regarding the material, DQBD printed withHigh Yield PA11 since it produces sturdy parts
that are impact resistant to shock and vibration.
It is vital that the snap-fit components exhibit
strength and high ductility due to their use.
Additionally, PA11 is eco-friendly and completely
bio-based from sustainable castor oil.

Document
Case
StudyTitle Here5It was essential to precisely
reproduce each snap-fit sothe Somnosync’s components
remain intact, and theuser’s sleep can be tracked
correctly.
Sebastian Hess

DQBD CEO and Founder6Testing the Somnosync
To validate the Somnosync, individual tests have been completed. To further authenticate the sleep mask,a larger case study will be conducted in a sleep-laboratory that tests how the Somnosync analyzes REM
sleep behavior disorders.

Case Study

The Somnosync is changing the way sleep can be diagnosed and treated, from the comfort of the patient’sown bed.

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