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Mask

Using an OSHA certified N95 Mask as a template, we designed the specifications to 3D print a prototype mask, but had to work on multiple iterations. For example, due to printing errors, the pieces did not fit together. Additionally, the original design was very uncomfortable on the doctors we tested it on. Through multiple trial and error sessions, we edited the design until the pieces were sized correctly and we added some extra pieces, foam and elastics, to make the masks comfortable for people who need wear them all day.

Design

We also realized that we didn’t have the resources to print disposable masks for every patient. Instead, we put our own unique spin on the design. We decided to create a base mask that could be easily sanitized and reused. We then sourced small, disposable filters that could be easily replaced and provided in bulk.. These filters could be replaced on the mask as needed, and had the same porosity as commercially available N95 masks. The design allows the filter replacements to be very fast and simple, so as to not tax the minds of the patients or first responders who are already knee-deep taking care of coronavirus patients.

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Filters

The filters meet HEPA filtration standard of 99.7% efficiency at 0.3 microns. A small 2 inch square of filter fabric can be replaced every 2-3 days, or daily if required. The masks were fit tested and aerosol tested, similar to any N95 mask testing.

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