3D Printed Contoured Mask with Removable Filter
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Solution Overview
Problem
Current face masks often cause irritation and discomfort due to improper fit, material sensitivity, and inadequate protection against airborne pathogens, leading to reduced compliance during pandemics.
Innovation Solution
A customized, contoured facial mask using 3D printing technology that matches unique facial contours, providing a large surface area contact without touching sensitive areas like the nose, glabella, or chin, and incorporating a removable air filter for bacterial and viral pathogen filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard face mask is used to provide protection against airborne pathogens, then protection is improved, but comfort and fit are worsened due to irritation and improper fit
Solution Approach 1:
The mask is divided into distinct functional zones: a rigid structural portion providing protection and a flexible cushioning portion providing comfort. This segmentation allows each zone to optimize its specific function without compromising the other.
Solution Approach 2:
Different regions of the mask have different properties: the rigid portion provides structural integrity and protection, while the flexible portion provides comfort and conformability to facial contours. This local differentiation resolves the contradiction between protection and comfort.
2Reliability
If a mask contacts sensitive areas like the nose, glabella, or chin to provide a secure seal, then protection is improved, but cosmetic changes and irritation are worsened
Solution Approach 1:
The mask applies sealing pressure only to non-sensitive areas of the face through its flexible cushioning portion, while avoiding contact with sensitive areas like the nose, glabella, and chin. This localized approach maintains seal quality without causing irritation or cosmetic changes.
Solution Approach 2:
The flexible cushioning portion acts as an intermediary between the rigid mask structure and the user's face, distributing pressure away from sensitive areas while maintaining the seal through conformability to facial contours.
3Reliability
If a non-removable filter is integrated into the mask to provide continuous filtration, then protection is improved, but ease of maintenance and filter replacement are worsened
Solution Approach 1:
The filtration system is segmented into a removable filter component that can be easily detached and replaced, while remaining integrated with the mask structure during use. This allows maintenance without compromising filtration effectiveness.
Solution Approach 2:
The filter transitions from a static integrated component to a dynamic removable component, allowing it to be easily replaced when needed while maintaining continuous filtration protection during normal use.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The mask offers increased comfort, improved fit, reduced cosmetic changes, and enhanced protection against airborne pathogens, ensuring a secure seal without causing pressure points or irritation, thus increasing compliance during extended wear.
Implementation Method 1
incorporating a removable air filter for bacterial and viral pathogen filtration
Data Source
AI summary
A face mask for extended wear by a user including a customized, contoured facial mask portion constructed and configured to cover and matingly contact a corresponding contoured surface area of a human face, preferably formed by 3D printing methods and materials. The face mask includes strap attachments and at least one strap for securing the customized, contoured facial mask portion to the face. The face mask includes at least one replaceable air filter for filtering out viral or bacterial pathogens.