vacuum forming mould to make coronavirus covid-19 facemask --------------------------------------------------------------------------------
For six months during lockdown, My project was to design a new 'Covid-19' mask.
The aim was to make it fast to produce and cheap on materials.
3d printing a mould and 'vacuum forming the mask seemed to be the best solution.
I now make a basic mask in 1 to 2 minutes, and a custom one in about 5 minutes.
I also designed various tools for making the post vacuum features easy to accomplish.
I use two (3mm activated carbon filters) with cotton wool sandwiched between them.(the thickness of the cotton wool dictates how easy or hard it is to draw breath through the filters). They are my personal choice.
Other filters can be used if preferred.
The moulds require no supports or rafts, and can be printed at standard resolution with just 20% infill.
The two round plugs should be located inside the two holes of the 'mask mould' prior to vacuum forming, then removed afterwards to allow the two holes in the mask mould to be used as drill guides for the two inhaling holes through the mask itself.
The 'exhaling drill guide' should be inserted into the front of the formed mask to guide the drill for the exhaling hole through the mask.
The 'mask draw guide' should be inserted into the underside of the mask itself and used to draw the outline shape of the mask for cutting away the waste plastic from the moulded mask.
The 'filter covers mould' is available in slim or deep, depending on the filter thickness to be used in the mask. There are also 2 corresponding sized 'filter cover drill guides'.
The 'filter drill guides' should be used to centralise drilling the holes through the filter covers and to act as supports to the vacuumed plastic while drilling. They are also used to guide the cutting of waste material from the filter covers. There are two sizes depending on which of the filter cover moulds are used, (slim or deep). . One of the 'filter drill guides' has a large central hole while the other has 9 smaller holes. It's for personal preference.
The transparent mask uses the vacuum formed 'filter covers' and is the quickest and most cost effective version. A self-adhesive foam strip should be fixed at the rear. Typically less than £1 to produce. With these types of filter covers the 3mm thick 'activated carbon filters' are 38mm diameter, and cost under 2p each.
The other two mask (rose gold colored) examples are custom masks that I sprayed on the inside before drilling and assembly. It's important if spraying to allow time for all spray fumes to dissipate.
They both use modified exhaling vents as inhaling filter holders. It very simple to do, just remove the internal lugs. I used nail clippers to do it.
The first (option1)has two inhaling filters, and an exhaling vent, while the second (option 2) has all three as inhaling filters.
These vent filter covers can be expensive when purchasing singly or in pairs, but if ordered in a pack of 20 units, they only cost about 7p each.
The mask design has 'eyebrows' and a sunken area around the upper filters.
Their main function is to help prevent rain from getting into the filters and to protect the filters from touch or damage. The end caps on the elastic will stop the elastic knots from undoing. With these types of filter covers the 3mm thick 'activated carbon filters' are 30mm diameter, and cost under 2p each.
On the two custom versions I used 'rubber car edging trim' around the edges of the mask, and on the rear of the edging I also added a self-adhesive foam strip, adhered to the rear of the 'rubber car edging trim.
I have a webpage that explains more information & has links to the various componants:
The is a youtube video here that follows the whole project from start to finish.
------------------------------------ This 3D model has not been approved by any regulatory agency and has not passed any laboratory tests. It was designed by me for my own personal use. It is not intended to replace any homologated mask, but to provide minimal protection.
Note: I am not a doctor and cannot give any assurance that this will work. Use it at your own risk.
If you like this mask and would like to help support my work you can either use the "Tip Designer" link or PayPal me directly at: https://www.paypal.me/cooperroy
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