A customized mask is manufactured by the process of: generating surface geometry data of a face of a patient, the surface geometry data corresponding to and representing a surface geometry of the face of the patient； generating original cushion geometry data using the surface geometry data； generating modified cushion geometry data using the original cushion geometry data； producing a rigid support member using the modified cushion geometry data such that it is shaped according to the modified cushion geometry data, the support member being made of a unitary material； and coupling a sealing flap to the support member, the sealing flap being structured to engage the face of the patient.
