How to 3D Print a Face Mask That Can Pass a Hospital Fit-Test

This video is a tutorial for creating a 3D printed mask that has proven capable of passing a hospital fit-test, the same test used to evaluate the safety and effectiveness of n95 masks. This mask could potentially be helpful in the fight against the spread of COVID-19, especially in situations where proper PPE is unavailable or in limited supply, as it would be cheap and easy to manufacture, could be deployed anywhere in the world using local 3D printing resources, and could potentially be reusable after thorough disinfection.

The video covers the 3D printing of the mask and its components, the fitting of the mask to the wearer, creating filters for the mask, and final assembly.

While the mask created in this video has proven capable of passing a hospital fit-test, it is important to note that the sample size of the testing as well as the scope of the testing was limited. Anyone planning to wear a 3D printed mask should perform their own fit-testing to ensure their mask is functioning properly before use. This mask has not received approval for use as personal protective equipment from any regulatory agency or hospital administration and the creators of this video make no representations as to the safety or effectiveness of this mask. Use this mask at your own risk.

Known shortcomings of 3D printed masks that should be taken into consideration before use include:
– May cause skin irritation due to humidity within the mask
– May cause bruising or abrasion at the contact point between the mask and the face
– Due to the inflexible material of the mask, the mask may struggle to maintain an airtight seal in instances of exaggerated or rapid facial expressions. Be sure to test such facial expressions while performing your fit test to understand the limitations of your mask.
– The mask will reduce airflow to the wearer which could potentially cause lightheadedness with prolonged usage. These effects could be exacerbated by physical exertion, stressful situations, or pre-existing conditions. Before use, be sure to test the airflow of the mask to ensure it is sufficient and does not cause discomfort or symptoms. If you experience discomfort, dizziness, or any other symptoms while wearing the mask, withdraw to a safe location and remove the mask, while following all protocols for mask removal and disinfection.
– 3D printed filament has a low heat tolerance. Do not store 3D printed masks outdoors, inside a hot vehicle, or near radiators or furnaces. Avoid using warm water or heated drying when cleaning the mask. Exposure to heat could deform the mask or compromise its function.
– Blunt force applied to the mask, as might occur in a fall or a blow to the face, could cause serious injury to the wearer including blunt force trauma or lacerations. Do not use a 3D printed mask in active situations or in crowded environments.

In addition to these known shortcomings, there are potentially other unknown risks to wearing a 3D printed mask as PPE. Due to the shortcomings and risks, 3D printed masks should not be viewed as a replacement for proper PPE.