A novel fully automatic design approach of a 3D printed face specific mask: Proof of concept

Abstract

The use of high quality facemasks is indispensable in the light of the current COVID pandemic. This study proposes a fully automatic technique to design a face specific mask. Through the use of stereophotogrammetry, computer-assisted design and three-dimensional (3D) printing, we describe a protocol for manufacturing facemasks perfectly adapted to the individual face characteristics. The face specific mask was compared to a universal design of facemask and different filter container’s designs were merged with the mask body. Subjective assessment of the face specific mask demonstrated tight closure at the nose, mouth and chin area, and permits the normal wearing of glasses. A screw-drive locking system is advised for easy assembly of the filter components. Automation of the process enables high volume production but still allows sufficient designer interaction to answer specific requirements. The suggested protocol can be used to provide more comfortable, effective and sustainable solution compared to a single use, standardized mask. Subsequent research on printing materials, sterilization technique and compliance with international regulations will facilitate the introduction of the face specific mask in clinical practice as well as for general use.

A feasible route for the design and manufacture of customised respiratory protection through digital facial capture

“…It highlights the importance of considering the individual user’s face when evaluating the effectiveness of respiratory protection and, in the authors’ words, shows “A good quality respirator equipped with high-efficiency filters is not nearly enough to ensure a proper protection of workers”. A further novel and automated approach to move directly from stereophotogrammetry scan data to a customised design was demonstrated by Shaheen et al 21 combining the use of traditional facial landmarks and direct mapping of the facial contour to form the device design. The only notable drawback of these two approaches is the need to customise and produce the entire device for each user which adds significant time and cost to the process thus limiting the potential for scale-up.…”

Is additive manufacturing a magic bullet to resupply lacking PPE? Producing respirators and face shields during COVID-19 pandemic: A systematic review

“…18,19,43 It is worth emphasizing that the use of 3D face scanning techniques allows for producing a mask with the highest degree of adhesion, and thus, tightness. 5,11,18 In order to increase the comfort wearing of a face mask obtained using AM techniques, the use of soft rim, most often made of silicone, has become common. 5,22,34 Designs of a modified full-face diving mask with AM-made additives and an additional filter were also described.…”

“…Swennen et al used new generation smartphone with 2 cameras supported with Bellus3D app to generate individual 3D face scans. 11 Shaheen et al used 3D camera VECTRA® H1 (Canfield Scientific Inc., Parsippany, USA), 5 while Piombino et al used smartphone and Bellus3D application (Bellus3D, Campbell, USA). 18 These customized face masks can be complemented with a disposable filter membrane support, also designed using computeraided design -those masks become consistent PPE after quick assembly.…”

“…The last element, a soft rim, was made of TangoPlus photopolymer, a soft transparent rubber-like material. 5 Imbrie-Moore et al shared an idea to transform one N95 face mask into 4 new masks with the same properties. They used SLA technology.…”

“…These aspects made it a necessity to cover the face and disinfect all used surfaces. 4, 5 The global situation made it necessary for everyone to gain access to personal protective equipment (PPE). The pandemic created a great shortage in PPE and additive manufacturing (AM) was an alternative solution to this problem.…”