This 3D‑printable adapter allows you to attach standard 3M bayonet filters (e.g. P100, 6000/7000 series) to the outlet of a ResMed AirSense 10 CPAP machine. It fits into the factory inlet (the lid/cap will need to be removed), providing a secure, airtight connection to off‑the‑shelf respirator cartridges for enhanced particle filtration.
Changelog Version 1 - Uploaded.
Version 2 - Increased pipe internal diameter & created a tapered reducer from 3M fitting to inlet. Testing demonstrated a notable reduction in motor strain.
Key Features
Perfect fit for the ResMed AirSense 10 outlet (22 mm outer diameter interface)
Standard 3M bayonet mounting (26 mm bayonet lugs)
Orientation: Supplied file has optimum position for minimal supports
Installation
Testing & Validation
Fit‑check: After installation, run the CPAP at your usual pressure to confirm seal tightness.
Compatibility: Tested with ResMed AirSense 10 and 3M 6000‑series P100 filters only.
⚠️ Disclaimer & Risk Notice
Important: This adapter is not an FDA‑approved medical device. It has not been tested under all possible clinical or home‑use scenarios. By downloading and using this file, you agree that:
You assume all risk. You are fully responsible for verifying compatibility, fit, and airtightness before using in any therapy.
No warranties. This design is provided “as‑is,” with no guarantees of performance, safety, or biocompatibility.
Consult professionals. Always check with your healthcare provider or equipment specialist before modifying medical devices.
Limited liability. The designer and distributor of this file cannot be held liable for any injury, damage, or loss resulting from its use.
⚠️ Material Risk Notice
Off-gassing: PLA can slowly release trace VOCs (e.g. lactide, acetaldehyde) at room-temperature airflow.
Particle shedding: Layer lines and micro-gaps can liberate microplastics into the air stream.
Non-certified: PLA isn’t biocompatible or medical-grade—unsafe for direct respiratory exposure.
Moisture sensitivity: Even in dry air, hygroscopic materials (PLA, PETG) can absorb ambient moisture over time.
🔧 Best Practices
Material choice
PETG or Taulman T-Glase (PETT) for lower emissions and higher stability.
Print settings
Nozzle: 240 °C (PETG) | 250 °C (T-Glase)
Bed: 80 °C (PETG) | 60 °C (T-Glase)
Layer height ≤ 0.2 mm for smooth walls.
Post-process
Sand internal channels with fine (400–600 grit) paper.
Coat all airflow surfaces with an FDA-compliant, food-safe epoxy (cure ≥ 24 h).
Usage
Treat as temporary until you can switch to true medical-grade silicone or machined PEEK.
Replace coatings or parts every 6 months, or immediately if surface damage appears.
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