COVID-19 DIY Mask Respirator 3DP Cavity/Core Mold

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This is a DIY remake of Silvia Stroe's respirator mask, with a goal to create an N95-like mask from household items that scores high on fit tests during the coronavirus shortage. The files are for a two-part mold that sandwiches materials under heavy pressure to produce well-fitting masks. It was 3D printed using an Ender-3 with 0.5mm layers and a 0.8 nozzle, employing Hatchbox PLA - this setup supported several hundred pounds of clamping force via standard woodworking clamps. Three to four layers of paper towel, applied with a light coating of a 10:1 water/PVA solution from a spray bottle as a binding agent, worked effectively to form masks. The resulting masks showed decent structure but still allowed some filtered air to pass through the mold's holes where little pressure was applied. Two layers of vacuum bags with the same binding agent also yielded good results. Water/flour mixtures performed moderately well, though not as well as PVA. It would be great to test a mask molded using vacuum bags or paper towel on a TSI PortaCount Respirator Fit Tester if anyone has access to one - this mask truly fits well, thanks to Silvia Stroe's design. Silvia Stroe's respirator mask remake: Mask for Respiratory-Free Reanimation Venturi's ValveNo guarantees masks created from this mold design possess any medical value - they can certainly give you a sense of security though..If there are excellent ideas for filter materials or binding agents, feel free to share them in the comments and I'll be happy to test them out.