DIY 3D printed respirator

thingiverse

In the present pandemic situation where the mask has become an essential part of daily life, disposable masks pose another threat in addition to plastic pollution. Cloth masks are not always comfortable, air leaks from several places and washing and drying them is an extra burden. To address these concerns, a ruggedised respirator has been designed and built using 3D printing technology and household items. This respirator is an open-source project, which anybody can download and make. It has dual inlet filters with oneway valves which channel the filtered air and prevent exhaled air from filling up space inside the inlet filter assembly. The exhaled air is directed out of the respirator by an oneway valve through the exhaust port only. This ensures more comfort for prolonged usage due to more air circulation and lesser residual volume of the air inside the respirator. Several layers of filter material (customisable) can be used and easily replaced. Weighing at only ~80 grams, this respirator is also easy to dismantle and sanitise. Background: PETG (Polyethylene terephthalate glycol) 3D printing filament has been used to make the parts of the filter assembly. PET is the same plastic used to make water bottles, cold drinks etc. but ends up in mostly as a waste while some are recycled. PETG is a slightly modified PET with the added glycol to adapt for 3D printers. PETG is preferred over commonly used material, PLA ( poly acetic acid) because of its higher melting point and easy to 3D print. Also, PLA being a bio-polymer along with a lower melting temperature than PETG, is not recommended for making this respirator. The mask body is made of HDPE(high-density polyethene) plastic as it is soft and its slippery smooth surface makes it easy to sanitise compared to 3D printed parts. HDPE is one of the most abundantly used plastic (shampoo bottles, talcum powder, etc) in our daily life which also, unfortunately, ends up as waste. 3D printing HDPE is not so easy due to its tendency to deform at temperature variations. However, it is very easy to stitch pieces of HDPE using a temperature-controlled soldering iron. So the mask body is made out of an HDPE shampoo bottle. Other materials required are: Filter material (As desired or cut it out from an N95 type mask), Cycle tube for making, straps, valves, shampoo bottle or any bottle of HDPE material for making the mask body, (Download the template for mask body.PDF file for cutting out pieces for the mask body) Double-sided tape, foam for comfort and air sealing