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This study proposes an efficient, cost-effective analytical methodology involving computational fluid dynamics for improving the performance of industrial-grade gas mask canisters. Computational fluid dynamics and the quadratic Forchheimer equation, used for calculating high momentum loss, were applied for analyzing the flow fields of six gas mask canisters. Streakline flow visualization and compression tests were conducted to determine the design performance. The results indicated that the designed honeycomb passageway in the canister demonstrated superior aerodynamics and structural loading to the original design. The honeycomb passageway design enhanced the flow rectification and increased the passageway sizes, improving the effective flow-through area and reducing the inhalation resistance. Finally, an improved prototype was produced based on the honeycomb passageway design. Aerosol penetration and hydrogen cyanide breakthrough tests confirmed that the improved prototype achieved a P100-level filter efficiency performance and maintained a 60-min breakthrough time. Without replacing the raw material, the inhalation resistance and absorbency of the improved prototype reduced by 46.48% and 33%, respectively, compared with the original canister.

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