Modular respirator mask with many features and a great fit

Designed during the Hack the crisis Sweden hackathon on april 5:th 2020. 7th place in the ‘Save lives’ category.
https://www.youtube.com/watch?v=iNOUVH5OP8w

Hi everyone,

This respirator mask was designed with the intention to provide an open mask design to the 3D printing community. Our goal was to make it actually useful and reasonably comfortable for the wearer while at the same time having a great seal to the face. The mask is also designed to accept a number of attachments such as valves, filters or filter adaptors.

Material choice

Good fit and seal has been achieved by printing the main body out of TPU and giving the main body a wide and flexible lip that seals tightly to the face.

Valves and straps are also printed out of TPU, however, I would recommend a store bought elastic ribbon or rubber to be used for the headbands.

Components should be printed with the materials that are displayed at the end of each file name. You can also look at the pictures, TPU parts are white, PETG are gray.

Please pay special attention when printing and mounting the valve membranes, make sure no unintended holes and gaps are present in the finished part. Also make sure that the smooth side of the valve membrane is facing the valve housing. This way the valve will seal better.

Fit and Comfort

Some people experience discomfort around the upper nose area when wearing the mask, to alleviate this, you may make two small cuts to the upper seal. This is illustrated in one of the product pictures.

Filter material

There are many choices for the filter material itself.

Here’s a great article here describing the filtration capabilities of household items:
https://smartairfilters.com/en/blog/best-materials-make-diy-face-mask-virus/

Seems like vacuum cleaner bags are best at filtering the air but hardest to breathe through, probably a mask attachment with a larger filter area will make breathing easier.

If you would like to develop your own attachment, template.stl and template.stp files are provided.

TODO

• Evaluate softer materials, especially for the straps
• Add to the supported particle filters adapters
• Develop an attachment with larger filter area for easy breathability
• Different sizes, maybe child sizes?
• Add functionality to filter exhaled air, looks like the virus can spread even if one is asymptomatic
• Add second exhaust valve option
• Add exhaust valve cover option

All feedback is greatly appreciated, I will try to keep all parts up to date in accordance to community feedback.