Filter element that has a thermo-formed housing around filter material

Method for making a filter cartridge that is suitable for attachment to a respiratory mask. The method comprises the steps of (a) providing a mass of filter material; (b) providing a filter cartridge housing that has an inlet and outlet and a sidewall that includes sheet material; and (c) thermoforming the sheet material of the housing sidewall around at least part of the mass of filter material to place the housing sidewall in direct contact with the mass of filter material to encapsulate the filter material so that fluid is prevented from passing through the filter cartridge from the inlet to the outlet without being filtered by the mass of filter material.