A headgear device is disclosed comprising a crown section (524) and a strap section (526). Both sections include a skin-facing fabric layer (512, 502), an outer fabric layer (520, 508) and a foam layer (504, 506, 514, 518) between the fabric layers. The layers are laminated and thermoformed together to retain a desired shape and can include regions of varying height. The headgear has a thermoformed crown section and four strap arm sections which can attach to a sleep apnea face mask.
