Development of a New Reusable and User-Centric General-Use Mask for Averting Respirator Supply Crisis in the Healthcare Sector

Healthcare workforce implements general-use masks for low and/or moderate barrier protection in sterile environments. However, these masks are often unavailable in pandemic situations due to a strain on supply/demand logistics. In such cases, establishing development of respiratory protection within the organization may be beneficial. Our work presents one such novel method of designing customized masks by considering facial anthropometrics of the specific sample population. In fact, such a design may provide a more efficient fit with the users as compared to currently available masks, which are often designed for a much wider range of people. The protocol followed a fast-paced method of obtaining facial data (~2.8 mins/participant), and a data-driven approach for extracting design profiles. We have demonstrated the same through a pilot study, which involved recruiting a group of 7 participants with ethnic and gender variation. A total of 7 landmarks representing zygomatic process of the temporal, angle of mandible, zygomatic arch, nasal-maxillary region, and apex of nose, mid-lips and the chin were selected. Analysis included determining closest, mid-points, and farthest points for each landmark among the entire datasets. Results indicated that the landmarks: Apex of Nose, Midlips and Chin represented a straight-line path with a lateral shift of ~4.58 inches between the closest and farthest dimensions from the nose point, based on which the facepiece was designed. Meanwhile, geometric transformations consisting of several construction lines and bisectors were used along with obtained data from zygomatic arch, process of temporal, and angle of mandible landmarks to determine the contours of the straps for securing the mask. Our design addresses common issues in masks like discomfort around the ear, humidity, and reuse, by provision of a novel mounting method, fabric-based materials, and sleeve for replacement of filters, respectively. The proposed concept of the mask and the methods followed could also be applied in broader applications including manufacturing/construction and also daily-life activities besides hospital environments.