FIGS. 1-16D & 66A-92D disclose a large variety of methods of forming the headgear for use in combination with a breathing apparatus including a unitary plastic core within textile casings. In some configurations, the plastic core material penetrates or bursts-through the textile casing of the straps. Some configurations include over moulding, alignment posts, T-joints and joint housings with injection aperture. FIGS. 17-65 & 93A-94C disclose a large variety of different headgear arrangements including top strap, front strap, rear strap and pairs of straps extending from the mask above and below the ear to meet behind the ear. FIGS. 95-121B disclose a large variety of connectors connecting the headgear assembly to the mask assembly where the headgear, mask and connector form a closed loop the connector is disengaged with the mask assembly.