Philips Recalled Millions of Sleep Machines — The Foam Inside Was Making People Sick

The short version: On June 14, 2021, Philips Respironics — one of the biggest makers of CPAP and BiPAP sleep apnea machines in the world — announced a recall covering millions of devices. The reason: the foam used inside these machines to keep them quiet could break down over time, releasing tiny particles and potentially toxic gases that patients were breathing in directly through their masks, every night, while they slept. In 2024, Philips agreed to a $1.1 billion settlement to resolve the resulting personal injury cases. If you used one of these machines and developed lung problems, cancer, or another breathing illness, you may be eligible for individual money.

This page explains what the foam problem was, which machines were recalled, who may qualify, and how to find out if your specific device is included. If you want to go straight to the form, it’s at the bottom of this page.

What the Foam Problem Was — In Plain Terms

CPAP and BiPAP machines use a motor to push air through a tube and into a mask that a person wears while sleeping. Because that motor creates noise, manufacturers put foam inside the machine to absorb the sound and make the device quieter. Philips used a specific type of foam called polyester-based polyurethane foam, sometimes shortened to PE-PUR foam.

The problem Philips discovered — and that the FDA confirmed — was that this foam could break down inside the machine over time, especially when exposed to heat, humidity, or certain cleaning products like ozone cleaners. When the foam breaks down, it releases two things:

• Tiny foam particles. These are small pieces of the foam material itself, which can travel through the air hose and into the mask. People using the machine breathe these particles directly into their lungs, night after night.
• Potentially toxic gases. As the foam degrades, it can also release chemical gases. The FDA classified some of these as potentially carcinogenic — meaning they may cause cancer.

Patients who used these machines had no way of knowing this was happening. The foam breakdown is not something you can see or smell. People were simply breathing through their machines as prescribed, unaware that something was degrading inside.

What Philips Said About the Recall

Philips issued the recall on June 14, 2021, and it was classified by the FDA as a Class I recall — the most serious type, reserved for situations where the product may cause serious injury or death. The recall notice was assigned FDA Medical Device Recall Database number Z-1965-2021.

At the time of the recall, Philips said the risk of harm was “real” but cautioned patients not to stop using their machines without speaking to a doctor. The company later replaced many machines, though the replacement process was widely criticized for being too slow and incomplete.

In 2024, Philips Respironics agreed to a $1.1 billion settlement to resolve personal injury cases brought by patients who had used recalled devices and suffered health problems. That settlement was filed in the MDL court: In re Philips Recalled CPAP, Bi-Level PAP, and Mechanical Ventilator Products Liability Litigation, MDL No. 3014, in the U.S. District Court for the Western District of Pennsylvania.

Which Machines Were Recalled

The recall covered a large number of Philips Respironics devices. The machines most commonly affected include the following series and models. If your specific device is not on this list, it may still be covered — submit your information and a legal team will check it against the full official recall list.

This list covers the most frequently cited models. The full FDA recall list is extensive. To check your specific device, look for the model name on the machine itself or in your prescription paperwork, then submit your information below.

How to Find Your Machine’s Model

The model name and serial number of your Philips machine are usually printed on a label on the bottom or back of the device. You may also find this information in any paperwork you received from your doctor or the equipment supplier (sometimes called a DME, or durable medical equipment provider). You do not need to still have the machine to check your eligibility — medical records showing you were prescribed a CPAP or BiPAP may be enough.

Who May Qualify

The personal injury portion of the settlement — the part that pays individual compensation to people who were harmed — generally requires two things:

• You used a recalled Philips machine. This means you were prescribed and used one of the recalled CPAP, BiPAP, or ventilator devices covered by the recall, at any point before the recall was issued or while the devices were still in use.
• You developed a qualifying health condition. The types of health problems most relevant to this settlement include lung problems (like lung cancer, pulmonary fibrosis, or other respiratory diseases), other cancers, or serious respiratory illnesses. The severity and timing of your diagnosis relative to your machine use will matter.

You do not need to currently own the machine. You do not need to have filed a complaint with the FDA or Philips. If you were prescribed a CPAP or BiPAP machine and later developed a breathing illness or cancer, submitting your information for a review is the right first step.

What Symptoms People Reported

After the recall was announced, patients who had used the machines came forward with a range of health issues they believed were connected to breathing degraded foam particles and gases. The most commonly reported problems included:

• Persistent cough, sometimes producing small dark or discolored particles
• Chest pain or tightness
• Shortness of breath that worsened over time
• Headaches and dizziness
• Respiratory infections that kept coming back
• New diagnoses of lung cancer, kidney cancer, or other cancers
• Pulmonary fibrosis (scarring of the lungs)

Not everyone who used a recalled machine will have experienced these problems. And not everyone with these symptoms will necessarily qualify. Whether your specific situation connects to the recalled device is something a legal team will evaluate with you — at no cost to you.

Common Questions

I returned my machine to Philips during the recall. Can I still have a case?

Yes. Returning your machine does not waive any legal rights you may have. What matters is how long you used the device before it was recalled and whether you developed a health condition connected to that use.

I no longer have my machine. Does that matter?

Not necessarily. If you were prescribed a Philips CPAP or BiPAP machine, your prescription records, your medical records, and records from your equipment supplier can establish that you used the device. You do not need to have the machine in your possession.

My doctor didn’t tell me to file a case. Should I still check?

Yes. Doctors are not lawyers and are not in a position to advise you on legal eligibility. Checking your eligibility is free, takes two minutes, and does not commit you to anything. If you used a recalled machine and have had breathing problems or cancer, the only way to know if you qualify is to have a legal team review your specific situation.

Is there a deadline?

Yes. All legal cases have filing deadlines. The recall was issued in June 2021, and the clock has been running since then. How much time remains depends on your state and your specific situation. The most important thing is not to wait any longer than necessary. Checking takes two minutes and costs nothing.

Does it cost anything?

The case check is free. If you proceed with a claim, there is no fee unless your case results in a recovery. You pay nothing out of pocket, ever, unless you win.