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Oxygen concentrators (OC) are medical devices that supply oxygen by separating nitrogen from the atmospheric air. The functionality of PSA-based OC majorly depends on internal pressure dynamics, cycle timing accuracy, orifice dimensioning for flow and pressure regulation, selection of zeolite, air moisture content, and others. This study aimed to develop an improved OC with sustainable performance by optimizing these key parameters. Initially, lithium and sodium-based zeolite adsorbents were experimentally compared, and it was determined that lithium-based 13X zeolite with particle size 0.4–0.8 mm is more effective for OC. An optimization study was performed for the orifice diameter for the required flow rate, purity, and pressure. The 1 mm hole diameter orifice was concluded to deliver the most optimal functionality. The results were validated via analytical and numerical study, which can further be …