MY FACE MASK: Mask with a replaceable filter.

Custom 3D printed mask with replaceable filter, obtained from a 3D scan of the wearer, an open-source project released.

WASP has developed a process that, starting from the 3D scan of the face, allows to customize and produce a tailored mask for every user.

The wearer can be scanned using photogrammetry with a standard smartphone camera from a distance of 1 meter. All the photos taken are then reprocessed to create a 3D mesh

 Our goal was to make the mask perfectly ergonomic, following the facial features as a second skin, a result that we obtained using Blender.

The material used is PCL: Polycaprolactone as it can be placed in direct contact with the skin.

PCL is a biomaterial widely used in the medical field, its melting point is 100°C, it doesn’t warp and there’s no need for a heated chamber to print it. The printed mask can be also hand-modeled to ensure a perfect fit using hot water (around 60°).

All masks are printed using Delta WASP 4070 INDUSTRIAL 4.0.

The idea is of a mask that can be sanitized and used many times. The filter is located in a central front slot, where it can be replaced. 
Here an interesting research concerning filters from Cambridge University.


It only takes about 4 hours to customize a perfect fit face mask, this reducing skin irritation and long-use related issues.

Open-source project: Here you can find how to learn photogrammetry, basics Blender tutorial (free and open 3D Creation software), the native blender file for design, and the .stl source files.

We decided to use photogrammetry to obtain a 3D scan of the wearer face since it’s the easiest method and can be performed using any smartphone camera. It can also be used a standard 3D scanner if available.

Instruction

One begins the process of making the custom mask by using a basic photogrammetry technique (https://en.wikipedia.org/wiki/Photogrammetry). Use a smartphone camera at a distance of 1 meter from the users head, circle around and take roughly 100 photos of the users face / head / neck at multiple angles, completing 360 degrees. These photos will be processed for the reconstruction of the person’s face mesh. This scan creates the base upon which a mask can be customized and adapted to fit the contours and shape of the users face.

[note: One may also use an off-the-shelf 3D scanner, however to keep this super DIY, we’re going to have you use a smartphone camera.

Follow our instruction in the download above

Use Meshroom to assemble the photos into a usable medium.
(Meshroom is free and open source photogrammetry software)
Meshroom Download: https://alicevision.org/#meshroom

After applying a basic model on the face mesh, the mask is made perfectly ergonomic by modeling it in 3D with Blender.

Blender: https://www.blender.org/download/
Follow our instruction in the download above

We recommend that you print with PCL (policaprolactone) filament. It is a low temperature bio-polymer that can remain in contact with the skin without causing irritation. PCL is already used in the medical field. Print settings should be at 100°C / 212°F with no infill. PCL does not shrink and there is no need to use a heated chamber. It takes about four hours of printing. The sample is 3d printed by Delta WASP 4070 IND 4.0.

When the print of the MY FACE MASK is finished, immerse it in hot water at about 60°C / 140°F in order to make it pliable so that it can be more closely adapted to the shape of the face. (One can also use a heat gun or hair dryer).

Cut the filter material to right dimensions and insert it into the mask.

By publishing this 3D application and how to replicate it, we want to make it clear that under no circumstances do we want to replace medical supplies. Our Team is available to develop tech projects at the service of the community.

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