Respirator Mask and valves by troygordon2

Last crawled date: 4 years ago

It isn't hard to do the right thing.
This is free for the whole world to do good with.
My thanks to the Montana Mask creators, Dr. Richardson and Dr. Zaugg for inspiring me to take the next step, and Jacob Morin for helping me with design.
Files should include the original mask (Mask 1), a ribbed design (Mask 2), the filter parts to be printed (and cast as needed) as well as a mold for the mask, which is my primary purpose in sharing. I want people with 3d printers to provide the mold to people without the 3d printers. Those people can buy silicone and gloves and produce multiple high performance masks at a relatively low cost.
1) 3d printing is a step, not the solution to creating functional masks. 3d printed masks are very hard, uncomfortable, and do not conform to create a seal on the face.
2) We need to make a mold, within which or on top of, we can coat with a flexible, durable material that can then hold the filtration element.
3) My approach is to use a material called DRAGON SKIN, made by the company Smooth on. It is exceptionally strong, flexible, easy to clean, and skin safe. 2 gallons costs roughly $200, small kits can be purchased for under $50 USD.
Spray the inside of the mold with Ease Release, a separating agent that ensures the silicone doesn't stick to the mold. Follow product guidelines. After the separating agent has been applied, Dragon Skin can be poured and roto cast/ sloshed and moved around the inside of the mold (around 250 grams worth per mask, spread over 3 separate pours in my prototype) and the VERY FAST cures quite quickly. It can be brushed around, or simply moved with a gloved finger until it starts to "gum up" and solidify. See link for example. There is zero vapor, at least as far as I can tell.
Purchase Dragon Skin here:https://www.reynoldsam.com/product/dragon-skin/
You will be casting copies in Dragon Skin, not molding a master object, I will upload a video shortly of me pulling casts from the mold.
Ease Release, a spray used to help the silicone separate from the master mold, can be purchased here:https://www.reynoldsam.com/product/ease-release-200/
4) Once the mask is of sufficient thickness, it can be pulled from the mold. You will have to punch 4 holes for the straps on the sides (I used a spent 308 shell and a hammer), and then cut out the center circle for the filter piece to fit through.
5) The filter piece looks like an Avocado with a threaded tube extending from it. This fits into the mask from within.
6) There is a small CIRCLE X piece that then fits into the front of the Avocado. This holds the filter material in place.
7) Place filter material over the CIRCLE X. Depending on length of the threads, you may need the securing nut to keep the AVOCADO smashed and tight into the silicone of the mask body, or the end cap may both hold the filter in place against the CIRCLE X and provide compression holding the AVOCADO firmly into the silicone body, which forms a seal. And a run on sentence.
7A) The AVOCADO X doesn't need the X piece printed out, but can be printed and used alone. If you're molding and pouring plastic copies, the AVOCADO NO X is much easier to mold and cast.
The Billings Clinic is currently purchasing medical grade filtering material from High Tech Filters, but you may be able to find something local that meets medical requirements.
https://www.flowmarkhightech.com/
This is not a complicated device, design, or mold. If I can make them in my basement, I would love to see big industry take the next step and pump these things out everywhere.
If we can print the molds and distribute them, almost anybody can make masks from home regardless of their 3d printing capability. It literally takes mixing cups or a gram scale, a Popsicle stick, and a pair of gloves. A separating agent will help the mold too, but overall the cost per mask becomes reasonably very quickly.
Go forth and do good things.