A method for fabricating a facial seal for use in a breathing assistance system is provided. The method includes capturing one or more images of a patient's face. The method further includes translating the one or more images into a set of data representing a three-dimensional structure of at least a portion of the patient's face and fabricating a facial seal to substantially conform to the patient's face based at least on the set of data, including fabricating at least a portion of the facial seal using rapid prototyping or a subtractive manufacturing technique. A method for selecting a facial seal for a breathing assistance system is also disclosed.