P100 Fit Tested COVID19 Mask - Unity

thingiverse

Based off of a traditional 3M respirator, this 3D-printed mask will accept standard 3M P100 filters (parts 2097 and 60923). According to Reuters, "An emergency stockpile of medical equipment maintained by the U.S. government has nearly run out of protective gear that could be useful to combat the coronavirus pandemic, according to two officials with the U.S. Department of Homeland Security." This disruptive virus should be met in kind with disruptive technologies. In the spirit of Salk, distributive manufacturing can enable forward thinkers to empower and protect their respective communities. Rather than waiting for the last ration of PPE to be consumed and for patients to be triaged in mass casualty scenarios, we should all plan accordingly and have redundancies in place. The mask has been fit tested and is ready to be utilized (by the physician we tested it with, documentation attached). Simply print this design (supports generated using Simplify3D or your favorite slicer), apply 12.7mm weather-stripping gasket so that 6.25mm protrudes beyond the margins of the mask, use any two 25.4mm elastic bands to secure (one just superior to lambda and one inferior to the inion), don and tighten. It is recommended that you use a gasket material (neoprene washer, vinyl dishwashing glove, blu-tak, dicor butyl seal tape, any material that has compressibility and can be made to fit this area) that is a minimum of 0.25mm thick, 24mm in diameter, and with a minimum of 20mm inside diameter hole cut (no more than 21mm). This will provide a surface for the filters to compress down into and prevent any (however trivial) air from entering the mask at this joint. I will be using stretch fittings for this area using TPU/Ninjaflex. Coming soon will be detailed instructions and updates. Grant money has been obtained to improve upon, test, and expand this design - which will include creation of an affordable and effective PAPR (grant monies thanks to Dr. Jim Latronica and the Pennsylvania Osteopathic Medical Association). In the worst-case scenario, an adapter will be available to allow for air filter material (MERV 15 or higher rating) to be used within printed cartridges in the event P100 filters are no longer available. There are three total files for the universal filter adapter, the female adapter is a press fit item into the bottom part. I would recommend using some type of gasket material (blu-tak, dicor butyl seal tape, silicone caulk, hot glue) to lay in the channel present on the top piece. This will accept 1" thick furnace air filter material (the higher the MERV rating the better, 15 and greater MERV recommended). Did you know that upwards of 10% of the healthcare workforce fails fit testing for N95? We will be utilizing an EinScan Pro 2x 3D scanner courtesy of Shining 3D to create custom facial interfaces printed from ninjaflex/TPU in order to make the "one size fits most" of the small, medium, and large to be a perfect fit 99% of the time (this includes custom facial interfaces for other brand masks, like the popular N95). Other work that has been completed as proof of concept: a CMV mechanical ventilator created from a bag valve mask, Arduino, stepper motor and driver. CT of unobtanium parts in order to create facsimiles reproduced through FDM. Feel free to share and modify this design. NOTE: mask.stl, mask_v2_with_CPR_valve.stl, and mask_without_valve.stl are the only versions that have successfully been fit tested as of this point (we have not made attempts on the alternate versions).