This article presents a computational and experimental study of contact pressure between six N95 filtering facepiece respirators (FFRs) and five newly developed digital headforms (small, medium, large, long/narrow, and short/wide). Contact interaction is simulated using the finite element method and validated by experiments using a pressure mapping system. The headform model has multiple layers: a skin layer, muscle layer, fatty tissue layer, and bone layer. Each headform is divided into five parts (two parts for the cheeks, one part for the upper forehead, one part for the chin, and one part for the back side of the head). Each respirator model comprises multiple layers and two straps. The simulation process has two stages for each respirator/headform combination. The first stage is to wrap the straps around the back of the headform and pull the respirator away from the face. The second stage is to release the respirator so that the respirator moves toward the face. Strap forces and contact interactions are generated between the respirators and the headforms. Meanwhile, a real-time surface pressure mapping system is used to record the pressures at six key locations to validate the computational results. There is a strong correlation between computational and experimental results (R(2) = 0.88). By comparing the pressure values from simulations and experiments, we have validated the simulation models.

This paper presents a computational fluid dynamics (CFD) simulation approach for the prediction of leakage between an N95 filtering facepiece respirator (FFR) and a headform and an infrared camera (IRC) method for validating the CFD approach. The CFD method was used to calculate leak location(s) and 'filter-to-faceseal leakage' (FTFL) ratio for 10 headforms and 6 FFRs.The computational geometry and leak gaps were determined from analysis of the contact simulation results between each headform-N95 FFR combination. The volumetric mesh was formed using a mesh generation method developed by the authors. The breathing cycle was described as a time-dependent profile of the air velocity through the nostril. Breathing air passes through both the FFR filter medium and the leak gaps. These leak gaps are the areas failing to achieve a seal around the circumference of the FFR. The CFD approach was validated by comparing facial temperatures and leak sites from IRC measurements with eight human subjects. Most leaks appear at the regions of the nose (40%) and right (26%) and left cheek (26%) sites. The results also showed that, with N95 FFR (no exhalation valves) use, there was an increase in the skin temperature at the region near the lip, which may be related to thermal discomfort. The breathing velocity and the viscous resistance coefficient of the FFR filter medium directly impacted the FTFL ratio, while the freestream flow did not show any impact on the FTFL ratio. The proposed CFD approach is a promising alternative method to study FFR leakage if limitations can be overcome.

N95 filtering facepiece respirator (FFR) dead space is an important factor for respirator design. The dead space refers to the cavity between the internal surface of the FFR and the wearer's facial surface. This article presents a novel method to estimate the dead space volume of FFRs and experimental validation. In this study, six FFRs and five headforms (small, medium, large, long/narrow, and short/wide) are used for various FFR and headform combinations. Microsoft Kinect Sensors (Microsoft Corporation, Redmond, WA) are used to scan the headforms without respirators and then scan the headforms with the FFRs donned. The FFR dead space is formed through geometric modeling software, and finally the volume is obtained through LS-DYNA (Livermore Software Technology Corporation, Livermore, CA). In the experimental validation, water is used to measure the dead space. The simulation and experimental dead space volumes are 107.5-167.5 mL and 98.4-165.7 mL, respectively. Linear regression analysis is conducted to correlate the results from Kinect and water, and R(2) = 0.85.

In recent years, there has been a concerted effort for greater job safety in all industries. Personnel protective equipment (PPE) has been developed to help mitigate the risk of injury to humans that might be exposed to hazardous situations. The human head is the most vulnerable to impact as a moderate magnitude can cause serious injury or death. That is why industries have required the use of an industrial hard hat or helmet. There have only been a few articles published to date that are focused on the risk of head injury when wearing an industrial helmet. A full understanding of the effectiveness of construction helmets on reducing injury is lacking. This paper presents a simulation-based method to determine the threshold at which a human will sustain injury when wearing a construction helmet and assesses the risk of injury for wearers of construction helmets or hard hats. Advanced finite element, or FE, models were developed to study the impact on construction helmets. The FE model consists of two parts: the helmet and the human models. The human model consists of a brain, enclosed by a skull and an outer layer of skin. The level and probability of injury to the head was determined using both the head injury criterion (HIC) and tolerance limits set by Deck and Willinger. The HIC has been widely used to assess the likelihood of head injury in vehicles. The tolerance levels proposed by Deck and Willinger are more suited for finite element models but lack wide-scale validation. Different cases of impact were studied using LSTC's LS-DYNA.

Respirators protect workers from hazardous airborne particles. It is important to evaluate respirator comfort and fit for all workers of diverse anthropometry as contact pressure plays a vital role. This paper presents the procedure and results of studying contact pressure of N95 filtering face-piece respirators (FFR) by using a finite element method. Finite element models of respirators and headforms have been improved based on a previous study. The headform model contains a skin layer, muscle layer, and bone layer. The whole facial area is divided into four parts (two areas for cheeks, one area for upper forehead, and one area for chin). Two N95 FFR models (one is onesize-fits-all and the other FFR has two sizes, i.e., small and medium/large) are used to simulate the interaction between the respirator and the headform. The results show that the respirator with two sizes provides better contact pressure distribution than the one-size-fits-all respirator. It has also been shown that the one-size-fits-all respirator works well for the large, medium, and short/wide headforms, but there are indications of potential leakages for the small and long/narrow headforms. For the respirator with two sizes, the medium/large size respirator works well for the large and long/narrow headforms, while the small size respirator works well for the medium, small, and short/wide headforms. The medium/large size respirator has potential leakages for the medium headform. Furthermore, the N95 FFR with two sizes has a more uniform pressure distribution than the one-size-fits-all respirator. Future studies are needed to validate these observations with human subjects.