Thermoformed Face Mask Frame

thingiverse

Innovate Against COVID-19: Thermoplastic Mask Frame. As we know, passive adaptation for surgical masks and even respirators is quite limited. While hospitals can provide fit tests, a reliable method of border sealing masks is needed to improve fit on the go. After reviewing the posterior harness device, 3D scan based frame, and rubber band methods, I decided to take a different approach to ensure proper sealing. A 7mm wide frame by 2mm thickness was printed completely flat with a skewed oval design. The thermoplastic frame is then heat molded to adapt to users' face with moderate pressure. This design mitigates any facial shape difference. Thermoplastic Custom Frame also takes into consideration of soft tissue compression (cheeks and chin) to provide a better all-around fitment. It takes approximately 3-5 minutes with a heat gun or hairdryer to properly adapt the shape of the frame to the individual's face. Alternatively, you can also use hot water at appx 75C to soften thermoplastic PLA. The temperature required to mold the face mask frame is dependent on 3D printing material used. I recommend using PLA as its lower thermal deformation temperature makes it an ideal choice for adapting shape to the face. Typically only area near nose and chin requires thermoforming. The frame device is then attached to the posterior harness from the previous project to ensure a backward and downward vector to ensure proper nasal bridge. Attach elastic or rubber bands to the frame via cut out area or clasps depending on the version used. The frame takes approximately 25 minutes to print on the FDM printer. Initial testing with level 2 surgical mask showed significantly more respiratory resistance when the frame device is used. This is a good indication seal has been dramatically improved. This is a work in progress and I will update and upload the CAD file asap. Steven Shao DMD Unicone Design Sunrise Dental Center