Flexible Mask (Valvy mod)

thingiverse

UPDATES -APRIL 9/2020: A new file, parts.zip, has been added with all the parts in separate files for those who want to try printing the base first and then the components on top. The gcode that prints the base first and then the components on top is included, specifically designed for the popular Ender 3 Pro (base_mask_challenge_v2.gcode). -APRIL 10/2020: A table has been added based on research about which material is best to use for filtration. It's recommended to use a portion of a surgical mask as a filter. The input valve now has a separator, allowing the valve to close freely when air is coming out. SUMMARY Modifications have been made to the original designs to meet specific needs due to a lack of masks available. The design utilizes surgical masks as filter material, making one surgical mask provide at least 10 filters. This means the TPU mask can be used five times (two filters in each filter bay). Parts: (Basic without valves) 1. Mask (TPU) (mask_gonchalox.stl) 2. Cartridge (TPU or PLA) (Flat_Filter_Cartridge.stl) 3. Separators (PLA) (Separator.stl) 4. Nose Clip (PLA) (nose_clip.stl) Parts: (With valves) 1. Mask (TPU) (mask_gonchalox.stl) 2. Cartridge (TPU or PLA) (Flat_Filter_Cartridge.stl) 3. Separator for the out valve (PLA) (Separator.stl) 4. Separator for the in valve (PLA) (Separator_valve_in.stl) 5. Nose Clip (PLA) (nose_clip.stl) 6. Valves (PLA)(Valve_v3.stl) 7. Valve separators (PLA)(Valve_Separator.stl) Assembly(no valves): Print the mask and join the upper part from outside, then reverse the mask to get the zippers pins inside the mask. Use hot glue or non-toxic glue to seal. Next, put filters in cartridges and fix them with separators. Then, put cartridges in both sides of the mask and the nose clip. The nose clip should be bent into an inverted U shape using heat air (hairdryer or a lighter). Straps can be used to hold the mask on your face (straps are being designed in TPU). Assembly(valves): The main difference is that valves with separators must be used, one for the in valve and one for the out valve. Insert the valve into the separator (2), then put each one into the mask in opposite directions. One valve allows air to enter while the other lets it exit. There are three versions of separators for valves depending on material thickness. I recommend using the 0.5mm space separator, allowing the valve to close freely; otherwise, it will be always open. Print settings: The most important setting is printing the face part at 0.1mm. To get a smooth finish, split the gcode to print the base first and then parts one at a time. A video explaining how to do this is available here: https://www.youtube.com/watch?v=-NunVWCT1nA I am also trying to find an easier way using Cura with less gcode interaction. This design was made by referencing the following designs: https://www.thingiverse.com/thing:4224005 https://www.thingiverse.com/thing:4177128 Please check those designs for more details and instructions, or additional parts that could fit this design. Disclaimer: This is a proof of concept and not intended to replace masks used by medical professionals fighting against COVID-19. It may potentially decrease airborne contaminants breathed in or expelled. I recommend using this mask as a substitute for a surgical mask (or even an N95 mask) if you don't have access to one.