Montana Mask with LARGE filter area

thingiverse

I've found the Montana Mask to fit extremely well after molding it with hot water. It passed an official Fit Test, which none of the brands of N95 masks at work have ever achieved for me. In fact, it's more comfortable than any surgical mask I've ever worn. My only concern is that the filter size is too small and the Work-Of-Breathing (WOB) is excessive. However, there are several modifications to this mask on www.thingiverse.com that increase the filter area. I experimented with one of them, known as the Utah modification, which adds a lot of complexity, weight, and bulk to the mask. I've since modified the Montana Mask in Fusion 360 to have a much larger filter area without changing its fit or bulk. This has reduced the WOB to undetectable levels. I'm including pictures of the 'stock' Montana Mask in tan, as well as my modified one in yellow. I've also made the strap holes larger. For those with access to a 3D printer, here's my recipe for a fast print with excellent results: Material: PLA or PLA+ Nozzle size: 0.6mm (which makes the print faster) Layer height: 0.32mm Infill percentage: 20% (not critical, and I don't think there is any infill) Print temperature: 200C, bed at 50C (I don't think the bed needs heating) Print speed: 80mm/s, wall speed at 40mm/s Generate support: YES (only needed on the mask itself) Bed adhesion: Use BRIM for the mask, and nothing for the filter frame Finish the mask with a window gasket and heat mold it (only specific areas) according to the Montana Mask project directions. You can find these instructions at www.makethemasks.com. I'm using surgical mask material for my filter, which yields 2-4 filters per mask. This is a remix of the files from the www.makethemask.com site.