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So Basic

An open source, disposable and flexible respirator designed for emergency use. Ships flat and folds like origami.

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Safety

This respirator is not certified and is only offered as a potential solution when better alternatives are not available.

This respirator is not NIOSH certified or FDA approved. Please use your best judgement and discretion before wearing this mask and observe the guidelines recommended by the CDC and public health departments. We do not claim that this mask is guaranteed to keep you protected from COVID-19.

This device is currently in the testing phase at hospitals. Basic tests have been conducted on the current 65mm filter design and results from fit testing will be published soon. If you are a hospital or clinician interested in reviewing this design, please email basicrespirator at gmail for an evaluation kit.

Design

Easy to make, customized to fit and generates minimal waste.

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Like folding a paper airplane

A sheet of Tyvek™ or any other textile is transformed from a 2D flat pattern into a 3D form with a few simple folds, like origami. No sewing is required and the mask can be discarded after use.


The entire mask weighs 0.68oz (19.5g).
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Custom fitting with an airtight seal

The respirator ships and stores flat with preapplied adhesive. The mask assembles in minutes and the wearer can adjust it for a custom fit with an airtight seal. Tyvek™ is flexible enough to move with the wearer's skin so that facial expressions and talking won't introduce gaping or fog glasses. Because Tyvek™ is a lightweight and breathable material, the mask can be worn comfortably for long periods while performing strenuous activity without causing lightheadeness or sores.

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3D printed filter assembly

A 3D printed filter assembly accepts an N95 or substitute filter. The entire assembly uses 9.5g of filament and prints in about an hour with no supports or cleanup. Depending on materials and printing technology, it can be discarded/recylced or sterilized between each use.

Materials

An adaptable design that uses materials commonly found in hospitals.

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The materials below are recommended for those that work in healthcare. We will continue to update this section as materials are tested and results are published. Please read the Safety section and consult with administrators before determining their use.

  • Tyvek™ 1073B, a high-density polyethylene that's antimicrobial. It's breathable, durable, tear resistant, meets regulatory requirements, is widely in medical packaging and compatible with sterilization processes. It bonds to adhesives well and doesn't seem to cause paper cuts.
  • Filter: N95 filter, Halyard H600 sterilization wrap, fiberglass-free MERV 15+ air filter or multi-layered polypropylene
  • Inner seal: 1/8 inch adhesive-backed neoprene (antimicrobial preferred)
  • Gasket: 1/16 inch adhesive-backed neoprene (antimicrobial preferred)
  • Adhesive: Autoclavable double-sided
  • Nosepiece: Aluminum 85mm length
  • Straps: self adhesive bandage wrap or polypropylene strips
  • 3D printed filter assembly: the VA recommends printing respirators in Nylon using MJF. Form Labs' Surgical Guide Resin and Dental Resin are autoclavable. For FDM printing, PETG is preferred.
Assembly

Parts print in about an hour, ship flat and assembles in minutes.

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Fold into shape using the adhesive tabs, add a neoprene strip and adjust for an airtight seal. Insert the filter assembly with an N95 filter and tie on the straps. The mask is designed to last for an entire shift and should be discarded after use.

Contributors

Who's behind this project

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Hunter Futo: Designer, Engineeer, Inventor

Hunter is a multidisciplinary designer-engineer with a small digital fabrication lab in Los Angeles. She is experienced in industrial & soft goods design (Fusion 360, Rhino) digital fabrication (CNC milling, laser cutting, 3D printing) hardware electronics (circuit design, microcontrollers, robotics) and software programming (javascript, python, C++). She also programs and folds computational origami.

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Contribute

This project needs more bright minds to speed up its development. Email basicrespirator at gmail, visit the GitHub repository, the NIH 3D Print Exchange, JOGL, or Thingiverse if you'd like to contribute.