Primary Challenge Objective: Design a universal fit face mask that conforms to any users face, not allowing for any air pathways other than through the filter element. With nearly with nearly 600 entrants Alliance PCB Solutions took top honor; competing amognst teams from Carnegie Mellon University and National Institute of Standards & Technology (NIST) to name a few.

Additional requirements included designing a mask that was to be manufactured 100% using 3D print technology, ease of print, ease of assembly and ease of use.  With less than 5-days to design / develop / print and test the viability of the mask,

• Alliance PCB Solutions fulfilled the challange.

Armed with five different head scan models for reference, Alliance PCB Solutions determined common features were represented in each of the models provided and leveraged the common data points to create the initial contour.

A combination of rigid and flexible 3D print materials were utilized to create the final product.  The front uses a flexible and stretchable 3D print material that stretches over the replaceable filter element, similar to a cell phone skin cover.

The “Face Cup” also uses Ninja Flex.  It was contoured by meshing multiple head scan models for a common contour, but yet still allows for additional flexibility to further contour to end users face.

All elements form an air-tight seal, so no compromised pathways.
The mask assembles in 30-seconds, completely reusable after cleaning & filter replacement.

No support structure required for 3D printing and no post-process time required.

Multiple attachment methods.

Filter element for the purpose of this challenge – P95 respirator filter refill commonly found at any hardware store in the paint section.

More details on the challange can be found on America Makes website at: https://www.americamakes.us/america-makes-announces-top-designs-of-fit-to-face-mask-design-challenge/