Fabrication has been attempted. Female molds based on the part designs similar to those described above were fabricated by 3D printing (UP Box, ABS material). These were used to cast silicone parts. Silicone elastomer (Eco-Flex 0010, Smooth-On Inc., PA, US) was mixed and poured into the molds. They were then degassed in a vacuum chamber at 200mbar for 10 minutes prior to removal of excess elastomer. Parts were then cured for 15 minutes at 65C.
The samples did not have a sufficiently large air gap to allow for insertion of tubing for air transport. Additionally, the top and bottom parts of the samples adhered to each other due to the “stickiness” of the silicone material and its low rigidity. As they would inevitably collapse onto each other due to their high weight, the sticking of sides became unavoidable.
While fabrication was not pursued further within this project, the concept is believed to still be viable. Further fabrication may involve systematic variation of various geometric parameters (e.g. thickness) to determine the ideal design parameters. Additionally, higher strength elastomers may be used.
Alternate geometries are also being considered, such as simple straight channel patches with attachment points above the eyebrows and at the rims of the eyelids. These could be fabricated using thin, dry materials which can crumple under vaccum and then uncrumple, or expand under pressure, such as the plastic of common grocery plastic bags.