Next-Generation Custom-Fit Reusable Respiratory Protective Device with Continuous Fit Monitoring - Part II: Continuous Fit Monitoring.

Filtering facepiece respirators (FFRs) are manufactured in discrete sizes, with some models being limited in accommodating the fit of some sex and race combinations. This study presents the development of a custom-fit respiratory protective device (RPD) which conforms to a user's facial features and flexes and moves with facial movements during use. Our design also integrates a pressure-sensing network, which continuously monitors fit and will alert the user when the fit is compromised. In this Part II of the three-part series, we design and incorporate a continuous fit monitoring system in the RPD designed in Part I to enhance its role in protecting users from inhalation hazards in an effective manner during its use. The fit monitoring system comprises a fabric-based sensor network integrated into the RPD and an Android-based App designed to alert the user when the pressure at the faceseal falls below a given threshold established during the initial configuration of the RPD for the user. We also develop algorithms for the incorporation of the sensor slots and data buses into the custom-fit RPD using the Taxonomy of Landmarks defined in Part I. We enhance the structure developed in Part I to secure the sensor network during the use of the RPD. We develop algorithms for customizing a fastening hub to suit the head profiles of individuals to enable them to don the RPD quickly, easily, effectively, and in a repeatable manner. We demonstrate the successful application of the total design methodology by creating digital prototypes for three individuals with different facial profiles and make further advances to our goal of ensuring equitable respiratory protection for all including children, for whom RPDs are currently limited.