3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators
Background: In response to supply shortages caused by the COVID-19 pandemic, N95 filtering facepiece respirators (FFRs or “masks”), which are typically single-use devices in healthcare settings, are routinely being used for prolonged periods and in some cases decontaminated under “reuse” and “extend...
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| Format: | Article |
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Springer Science and Business Media LLC
2021
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| Online Access: | https://hdl.handle.net/1721.1/130941 |
| _version_ | 1826198896002465792 |
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| author | McAvoy, Malia Bui, Ai-Tram N. Hansen, Christopher Plana, Deborah Said, Jordan T. Yu, Zizi Yang, Helen Freake, Jacob Van, Christopher Krikorian, David Cramer, Avilash Smith, Leanne Jiang, Liwei Lee, Karen J. Li, Sara J. Beller, Brandon Huggins, Kimberley Short, Michael Philip Yu, Sherry H. Mostaghimi, Arash Sorger, Peter K. LeBoeuf, Nicole R. |
| author2 | Massachusetts Institute of Technology. Department of Nuclear Science and Engineering |
| author_facet | Massachusetts Institute of Technology. Department of Nuclear Science and Engineering McAvoy, Malia Bui, Ai-Tram N. Hansen, Christopher Plana, Deborah Said, Jordan T. Yu, Zizi Yang, Helen Freake, Jacob Van, Christopher Krikorian, David Cramer, Avilash Smith, Leanne Jiang, Liwei Lee, Karen J. Li, Sara J. Beller, Brandon Huggins, Kimberley Short, Michael Philip Yu, Sherry H. Mostaghimi, Arash Sorger, Peter K. LeBoeuf, Nicole R. |
| author_sort | McAvoy, Malia |
| collection | MIT |
| description | Background: In response to supply shortages caused by the COVID-19 pandemic, N95 filtering facepiece respirators (FFRs or “masks”), which are typically single-use devices in healthcare settings, are routinely being used for prolonged periods and in some cases decontaminated under “reuse” and “extended use” policies. However, the reusability of N95 masks is limited by degradation of fit. Possible substitutes, such as KN95 masks meeting Chinese standards, frequently fail fit testing even when new. The purpose of this study was to develop an inexpensive frame for damaged and poorly fitting masks using readily available materials and 3D printing.
Results:An iterative design process yielded a mask frame consisting of two 3D printed side pieces, malleable wire links that users press against their face, and cut lengths of elastic material that go around the head to hold the frame and mask in place. Volunteers (n = 45; average BMI = 25.4), underwent qualitative fit testing with and without mask frames wearing one or more of four different brands of FFRs conforming to US N95 or Chinese KN95 standards. Masks passed qualitative fit testing in the absence of a frame at rates varying from 48 to 94 % (depending on mask model). For individuals who underwent testing using respirators with broken or defective straps, 80–100 % (average 85 %) passed fit testing with mask frames. Among individuals who failed fit testing with a KN95, ~ 50 % passed testing by using a frame.
Conclusions: Our study suggests that mask frames can prolong the lifespan of N95 and KN95 masks by serving as a substitute for broken or defective bands without adversely affecting fit. Use of frames made it possible for ~ 73 % of the test population to achieve a good fit based on qualitative and quantitative testing criteria, approaching the 85–90 % success rate observed for intact N95 masks. Frames therefore represent a simple and inexpensive way of expanding access to PPE and extending their useful life. For clinicians and institutions interested in mask frames, designs and specifications are provided without restriction for use or modification. To ensure adequate performance in clinical settings, fit testing with user-specific masks and PanFab frames is required. |
| first_indexed | 2024-09-23T11:11:38Z |
| format | Article |
| id | mit-1721.1/130941 |
| institution | Massachusetts Institute of Technology |
| last_indexed | 2024-09-23T11:11:38Z |
| publishDate | 2021 |
| publisher | Springer Science and Business Media LLC |
| record_format | dspace |
| spelling | mit-1721.1/1309412022-10-01T01:57:00Z 3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators McAvoy, Malia Bui, Ai-Tram N. Hansen, Christopher Plana, Deborah Said, Jordan T. Yu, Zizi Yang, Helen Freake, Jacob Van, Christopher Krikorian, David Cramer, Avilash Smith, Leanne Jiang, Liwei Lee, Karen J. Li, Sara J. Beller, Brandon Huggins, Kimberley Short, Michael Philip Yu, Sherry H. Mostaghimi, Arash Sorger, Peter K. LeBoeuf, Nicole R. Massachusetts Institute of Technology. Department of Nuclear Science and Engineering Background: In response to supply shortages caused by the COVID-19 pandemic, N95 filtering facepiece respirators (FFRs or “masks”), which are typically single-use devices in healthcare settings, are routinely being used for prolonged periods and in some cases decontaminated under “reuse” and “extended use” policies. However, the reusability of N95 masks is limited by degradation of fit. Possible substitutes, such as KN95 masks meeting Chinese standards, frequently fail fit testing even when new. The purpose of this study was to develop an inexpensive frame for damaged and poorly fitting masks using readily available materials and 3D printing. Results:An iterative design process yielded a mask frame consisting of two 3D printed side pieces, malleable wire links that users press against their face, and cut lengths of elastic material that go around the head to hold the frame and mask in place. Volunteers (n = 45; average BMI = 25.4), underwent qualitative fit testing with and without mask frames wearing one or more of four different brands of FFRs conforming to US N95 or Chinese KN95 standards. Masks passed qualitative fit testing in the absence of a frame at rates varying from 48 to 94 % (depending on mask model). For individuals who underwent testing using respirators with broken or defective straps, 80–100 % (average 85 %) passed fit testing with mask frames. Among individuals who failed fit testing with a KN95, ~ 50 % passed testing by using a frame. Conclusions: Our study suggests that mask frames can prolong the lifespan of N95 and KN95 masks by serving as a substitute for broken or defective bands without adversely affecting fit. Use of frames made it possible for ~ 73 % of the test population to achieve a good fit based on qualitative and quantitative testing criteria, approaching the 85–90 % success rate observed for intact N95 masks. Frames therefore represent a simple and inexpensive way of expanding access to PPE and extending their useful life. For clinicians and institutions interested in mask frames, designs and specifications are provided without restriction for use or modification. To ensure adequate performance in clinical settings, fit testing with user-specific masks and PanFab frames is required. 2021-06-14T19:27:36Z 2021-06-14T19:27:36Z 2021-06 2020-07 Article http://purl.org/eprint/type/JournalArticle 2524-4426 https://hdl.handle.net/1721.1/130941 McAvoy, Malia et al. "3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators." BMC Biomedical Engineering 3, 1 (June 2021): 10. © 2021 The Author(s) https://doi.org/10.1186/s42490-021-00055-7 BMC Biomedical Engineering Creative Commons Attribution 4.0 International license https://creativecommons.org/licenses/by/4.0/ application/pdf Springer Science and Business Media LLC BMC |
| spellingShingle | McAvoy, Malia Bui, Ai-Tram N. Hansen, Christopher Plana, Deborah Said, Jordan T. Yu, Zizi Yang, Helen Freake, Jacob Van, Christopher Krikorian, David Cramer, Avilash Smith, Leanne Jiang, Liwei Lee, Karen J. Li, Sara J. Beller, Brandon Huggins, Kimberley Short, Michael Philip Yu, Sherry H. Mostaghimi, Arash Sorger, Peter K. LeBoeuf, Nicole R. 3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators |
| title | 3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators |
| title_full | 3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators |
| title_fullStr | 3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators |
| title_full_unstemmed | 3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators |
| title_short | 3D Printed frames to enable reuse and improve the fit of N95 and KN95 respirators |
| title_sort | 3d printed frames to enable reuse and improve the fit of n95 and kn95 respirators |
| url | https://hdl.handle.net/1721.1/130941 |
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