COVID-19 Face Mask Emergency for any filter material

I’ve taken the liberty of improving the open-source design released by Dr. Zaugg recently for 3D printing a mask that uses a 2″x2″ piece of filter material (they’re saying they can use a single N95 mask to make 4+ filters for the reusable 3D printed parts. I wanted to make a mask that could use any thickness of filter material (within reason) and provide a positive seal.

Dr. Zaugg’s website for reference: https://longliveyoursmile.com/3d-printable-mask-for-covid-19/

Due to these parts being printed in rigid material like PLA, PETG, ABS, etc… This mask is not a size fits all situation.

Included is a 3D printable Scale to measure your face with 3D print scaling in 2.5% incruments from 100% to 40% and up but i got lazy and didn’t mark the +100% increments. Measurement is from bridge of your nose to point of chin (see diagram of my favorite theoretical physicist). Make sure to scale all the mask parts by the same amount!

I went through quite a few iterations to get the threaded geometry to work correctly without post processing. The only parts that need to have a finer layer height than 0.2mm are the Acme screws (I use PrusaSlicer variable layer height to print the threaded sections at 0.07mm layer height on my MK3s).

Basic concept is a 2″x2″ piece of material (N95 mask, Surgeon Mask, Medical grade cloth, etc) is sandwiched between the Green main mask and the blue “Sandwich Plate”. The plate has an energy concentration protrusion that should greatly increase the sealing off of whatever mesh is clamped between the 2 pieces (we use this type of feature on face seals for hydraulic breathers). What does the clamping are Qty. 4 3d printed thumb screws.

Also the models can be scaled up and down easily but might require trimming of the filter media.

I’m going to play with slitting some tygon tubing or surgical tubing to place around the edge to help sealing further.

Other then the 3d printed parts the assembly will need:

Qty. 1, 2″x2″ flat(ish) filter media

Qty. 2, 6-8″ elastic bands (I was thinking reusing the elastic from N95 or surgeon masks, rubber bands in a pinch).