Reusable, transparent, and reconfigurable N95-equivalent Respirator Masks: design, fabrication, and trials for enhanced adoption

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Abstract The COVID-19 pandemic has necessitated the wide use of facial protective equipment (FPE), by the general population, to combat viral spread. As an unfortunate consequence, the limitations of current FPE have been exposed, due to its technology having not improved significantly, despite medical environmental facemasks being used for over 100 years. This is particularly a problem with healthcare workers, who must wear facemasks or respirators for long periods, often several hours. These problems include fogging of eyewear, improper fitting, discomfort to the wearer, and hindered communication between individuals. In addition, the materials made in commonly available FPE can often be harmful to the environment, and their disposal can generate a large amount of hazardous landfill waste when used in present day quantities. The proposed research seeks to remedy this by developing new FPE designs. The first of these will be an improvement to the strapless facemask designed by SEEUS95, Inc. (New York, NY) known as the SEEUS95 respirator mask. The current half-mask design will be tested and trialed by volunteers, as well as modified to create a modification child-size version. The SEEUS95 masks features an eco-friendly new filter design and cartridge using natural materials (i.e., air-blown PLA) with no polypropylene, the first of its kind in air filtration. In tandem, the second FPE design to be studied will be an improved version of the X-mask, designed by the Chen laboratory. The design will be improved by adding a silicone padding to improve fitting and comfort, as well as incorporating the eco-friendly respirator design of the SEEUS95 masks and a novel filter design implementing contour airways (inspired by the morphology of the human gut and its ability to extract nutrients). Human subjects’ trials will test the designs for efficacy, and surveys will extract users’ opinions regarding whether they prefer the new or already available FPE, allowing them to elaborate on their desired key features for our design focus. The outcomes of this study will lead to improved FPE designs for better communication, comfort, and environmental outcomes, without sacrificing the safety of the wearer or those he/she encounters. The clear FPE will not only benefit those with hearing loss or difficulties in communications, as well as healthcare workers and first responders, but will also increase the likelihood of adopting and adhering to such FPE by the general public. The improved designs offer an effective manner to combat the effects of COVID-19, and could be instrumental in preventing the spread of virus should similar situations arise in the future. The outcomes will set the stage for Phase II research that aims to further examine and improve on the efficacy of these innovative FPE, and integrate with advanced sensing techniques for continuously monitoring human health conditions such as fever, couching, and chills. Ultimately our research and prototypes will garner increased adoption among the general public and provide better protection, social connection, and communication for our health care professionals. Altogether, these innovative FPE can also fight against climate change and air pollution, for example, by protecting people from wildfire smoke hazards.