[ARCHIVED THREAD] - 3D Printed N95/surgical mask emergency substitute. Now: purchase through the EE! (Page 3 of 7)
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Quoted: Why no support grill? Also, can't really see from the pics, is there a pinch groove for the filter media? Going to go searching for the cad files here in a bit. There are spherical locking "tabs" for retention, which also pull the filter tight over the mask. |
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Don't know if it will do any good, but I just got done talking to Amazon customer service. Tried to convince them to move printer filament up on their list of priorities. I only have 6 rolls of various filaments here. 3 are pla, the rest are TPU, Ninja Flex, and PETG. Less than a full roll of each. Wouldn't take too many screw ups to run out and still not have a functioning mask. An estimated ship date 30 days out is crazy for something that can be used to protect peoples health right now. I'm going to be honest here. I don't really care about a mask for me. I'm at home 99% of the time and currently have a beard. Won't do me any good. I do however, have a wife who is an NP and a 2 year old daughter that I would like to have a mask ready for. Might even give a few away to friends/family members since I'm the only one who prints. A mask might come in handy in the future for shop work too. Especially if it fits under a welding helmet. |
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Quoted: Don't know if it will do any good, but I just got done talking to Amazon customer service. Tried to convince them to move printer filament up on their list of priorities. I only have 6 rolls of various filaments here. 3 are pla, the rest are TPU, Ninja Flex, and PETG. Less than a full roll of each. Wouldn't take too many screw ups to run out and still not have a functioning mask. An estimated ship date 30 days out is crazy for something that can be used to protect peoples health right now. |
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"Fulfilled by Amazon" Free shipping Wed April 22 on everything. That's not a supply issue. That's a priority issue. I tried to explain that people were printing masks with the filament. I also tried to explain that keeping people occupied printing keeps them at home and away from others. I made sure to mention that some masks were being donated to those in healthcare and to others in need. |
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Quoted: For hard plastics, Atomic filament is still going last I checked. Filastruder is going, as well as Matter Hackers I believe. Quoted: Quoted: Don't know if it will do any good, but I just got done talking to Amazon customer service. Tried to convince them to move printer filament up on their list of priorities. I only have 6 rolls of various filaments here. 3 are pla, the rest are TPU, Ninja Flex, and PETG. Less than a full roll of each. Wouldn't take too many screw ups to run out and still not have a functioning mask. An estimated ship date 30 days out is crazy for something that can be used to protect peoples health right now. |
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First attempt failed 5 layers in. Partial clog or something. Started sputtering and shut down. Turned it up 5 more degrees and we'll go again. Fail #2 on layer two. Drop the bed, purge, go again. On #3 it's going to get a new nozzle. 50c bed 245c hot end 35mm/s (a little more conservative than I normally do) .2mm layer height Tianse 95a TPU Sovol SV01 direct drive head 50g 4hr print time for the mask. Filter cover to be done later. ETA. New nozzle time. ETA #2. Fail and Fail again. I'm starting to think my hot end has an oversized bore. The filament comes out all squigly when pulled back by hand. Maybe getting too hot and getting crammed in. Backed off to 235 and trying again. ETA #3. Starting to get a bit pissed. First couple layers always look beautiful. Then dribble, dribble, dribble, and we're printing with air. ETA #4. I wonder how far I can throw this thing. Something is screwy. I'm backed off to 30 mm/s for everything but travel. For some reason it is jumping up to at least double that for a trip around the perimeter and that's when the jamb happens. Then it slows down again. ETA #5. Dropped travel down to 30 also and it went from 4hrs to 5hrs. WTF? It should be printing most of the time. Not running from point to point. Bumped everything to 35 mm/s and it knocked 45 min off. Something isn't right, but we're going to try it again. ETA #6. It's currently printing and is quite a bit farther than before. I'm up to 3mm now. Something still isn't right. It's cranked up to 255c to keep it flowing, but something is fucked up. It's obviously printing interior walls and infill at about twice the speed as the exterior walls. All my speeds are set to 35 mm/s. If it dribbles again I quit and erbody 'round here is just going to have to hold their breath when they leave the house. |
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This may be the most perfect print ever to come from my crappy Maker Select V2! Well done! Feels like a pretty good (not perfect) seal is possible with PLA. This is promising. Printing one at 60% for the littluns. Attached File |
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The 90% design seems to fit my 10 year old fairly well. My initial concern of the tabs breaking did happen on first attempt to remove retaining ring from the mask Attached File I wonder if a small radius where the tabs meet the frame of the retaining ring to eliminate the stress riser would help? I'm currently printing another full size one in PLA+ with the 2mm ring to see how that comes out. Attached File |
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Quoted: The 90% design seems to fit my 10 year old fairly well. My initial concern of the tabs breaking did happen on first attempt to remove retaining ring from the mask https://www.AR15.Com/media/mediaFiles/331964/20200325_082221_copy_1612x784_jpg-1332432.JPG I wonder if a small radius where the tabs meet the frame of the retaining ring to eliminate the stress riser would help? I'm currently printing another full size one in PLA+ with the 2mm ring to see how that comes out. https://www.AR15.Com/media/mediaFiles/331964/20200325_074827_copy_1612x784_jpg-1332433.JPG I'd use petg at a minimum. I really did design it for abs or TPU. |
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Quoted: First attempt failed 5 layers in. Partial clog or something. Started sputtering and shut down. Turned it up 5 more degrees and we'll go again. Fail #2 on layer two. Drop the bed, purge, go again. On #3 it's going to get a new nozzle. 50c bed 245c hot end 35mm/s (a little more conservative than I normally do) .2mm layer height Tianse 95a TPU Sovol SV01 direct drive head 50g 4hr print time for the mask. Filter cover to be done later. ETA. New nozzle time. ETA #2. Fail and Fail again. I'm starting to think my hot end has an oversized bore. The filament comes out all squigly when pulled back by hand. Maybe getting too hot and getting crammed in. Backed off to 235 and trying again. ETA #3. Starting to get a bit pissed. First couple layers always look beautiful. Then dribble, dribble, dribble, and we're printing with air. ETA #4. I wonder how far I can throw this thing. Something is screwy. I'm backed off to 30 mm/s for everything but travel. For some reason it is jumping up to at least double that for a trip around the perimeter and that's when the jamb happens. Then it slows down again. ETA #5. Dropped travel down to 30 also and it went from 4hrs to 5hrs. WTF? It should be printing most of the time. Not running from point to point. Bumped everything to 35 mm/s and it knocked 45 min off. Something isn't right, but we're going to try it again. ETA #6. It's currently printing and is quite a bit farther than before. I'm up to 3mm now. Something still isn't right. It's cranked up to 255c to keep it flowing, but something is fucked up. It's obviously printing interior walls and infill at about twice the speed as the exterior walls. All my speeds are set to 35 mm/s. If it dribbles again I quit and erbody 'round here is just going to have to hold their breath when they leave the house. Also check filament tension, make sure your not swishing the hell out of the filament. You want just enough tension as to not slip. |
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Quoted: In my experience, pla is brittle enough that I don't think any small change in geometry would work to solve the issue. I'd use petg at a minimum. I really did design it for abs or TPU. To this point they have all been done in PETG (including this one). Trying one PLA+ right now with a little higher temp and less walls/infill to allow a little more flex overall. |
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Quoted: Interesting. PETG should be fine, as far as the flex goes. Quoted: Quoted: To this point they have all been done in PETG (including this one). Trying one PLA+ right now with a little higher temp and less walls/infill to allow a little more flex overall. |
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Quoted: Drop your print speed down to 10mm/sec, as well as your retraction speed. If it's successful, you can try to increase your print speed, but leave retraction alone. Change retraction settings to only retract when crossing open spaces, avoid crossing perimeters, and turn on combing. Also check filament tension, make sure your not swishing the hell out of the filament. You want just enough tension as to not slip. Retraction was off. Combing on. Tension backed off. The print finished and is useable, but with defects. The only stringing occurred as it was finishing up the wavy edge. The strap loops had some sagging towards the tips (max overhang). There is something wrong with the speed. It was really cruzing on the interior walls and slowing down to what appeared to be the correct speed for the exterior walls. I do normally print interior walls at a faster rate, but not this time. I shut down cura and will try restarting later. I'd like to try a kid sized version to conserve material. What's a good reference for scaling? Nose to chin? |
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Quoted: Retraction was off. Combing on. Tension backed off. The print finished and is useable, but with defects. The only stringing occurred as it was finishing up the wavy edge. The strap loops had some sagging towards the tips (max overhang). There is something wrong with the speed. It was really cruzing on the interior walls and slowing down to what appeared to be the correct speed for the exterior walls. I do normally print interior walls at a faster rate, but not this time. I shut down cura and will try restarting later. I'd like to try a kid sized version to conserve material. What's a good reference for scaling? Nose to chin? For a kid version, I would just start with a scale at 90%, see how it fits (if its going on a particular child), adjust from there. When making more scaling, make sure you start from the fresh model, otherwise you could be scaling the scaled model, and easily loose track. Don't forget the give the retainer the exact same scaling. |
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Quoted: I printed in PLA the 2mm version at 100% scale and 20%infil, I pushed and pulled on the tabs with enough force to leave indents on my fingers and it still didn't break. Quoted: Quoted: Quoted: To this point they have all been done in PETG (including this one). Trying one PLA+ right now with a little higher temp and less walls/infill to allow a little more flex overall. |
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Quoted: Yeah, I'm starting to this his filament may be wet. That will cause a massive loss in bonding strength. Material should be dry. I keep it in an airtight container with dessicant. I think it is/was layer bonding issue from printing too cold. Higher temps should help as well as reducing fan speed. My PLA+ one just finished. I put the retainer on and took it off a couple times and so far so good. Attached File |
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Finished my .6mm nozzle print with TPU. It would be usable, but its very stringy, bloby, and otherwise would need a lot of post-processing. I've always had troubles with TPU and larger nozzles though. TPU is just too oozy of a material for something like this with a big nozzle. And another note: the mask is much stiffer. With the .4mm nozzle, I ran 2 perimeters above the retainer ring area. I still ran 2 perimeters (to ensure air-tight printing) with the .6mm nozzle in the same area with a fully predictable result: thicker sides. In fact, with the .4mm and 2 perimeters, the contouring part of the mask is actually hollow, where its solid with the .6 nozzle. I'll switch to ABS and run a mask with the .6 nozzle. An ABS mask should work similar to a "surgical" mask, in that a sick person wears it to catch expelled droplets, so it doesn't have to have a perfect seal. A TPU mask should be used by those looking to avoid contraction, and be printed with a .4mm nozzle. |
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Quoted: Material should be dry. I keep it in an airtight container with dessicant. I think it is/was layer bonding issue from printing too cold. Higher temps should help as well as reducing fan speed. My PLA+ one just finished. I put the retainer on and took it off a couple times and so far so good. https://www.AR15.Com/media/mediaFiles/331964/20200325_123423_copy_784x1613_jpg-1332660.JPG |
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TPU mask with a PLA+ 2mm gap retainer. The retainer was printed with 0.28 layers, a 3 wall shell & 40% infill. It is holding 2 layers of felt with a paper towel layer between very securely. Not worried about breakage. Attached File I tagged the retainer rings with their gap size. I just did a model of the numbers 1 & 2, scaled to fit, then superimposed the appropriate one on the ring while in Cura prior to slicing. I also exported the result as an .stl for later use. Attached File |
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Quoted: TPU mask with a PLA+ 2mm gap retainer. The retainer was printed with 0.28 layers, a 3 wall shell & 40% infill. It is holding 2 layers of felt with a paper towel layer between very securely. Not worried about breakage. https://www.AR15.Com/media/mediaFiles/128622/DSCN6774_JPG-1332849.JPG I tagged the retainer rings with their gap size. I just did a model of the numbers 1 & 2, scaled to fit, then superimposed the appropriate one on the ring while in Cura prior to printing. I also exported the result as an .stl for later use. https://www.AR15.Com/media/mediaFiles/128622/DSCN6776_JPG-1332850.JPG Thanks for the idea. I'm not thinking completely clearly, this has actually kept me up at night since Saturday trying to get it as good as possible. |
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Quoted: Walmart.com has WYZ TPU for $31 and free 2 day shipping. Get it while its available! I have not tried this brand, but I ordered 2 spools myself  Quoted: Quoted: I really need to find some TPU to try out. Amazon taking a month to deliver isn't really helpful, lol Get it while its available! I have not tried this brand, but I ordered 2 spools myself The WYZ TPU should be here tomorrow. |
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.6mm nozzle with .3mm layer heights with ABS filament worked amazing (and fast) just like they should. If anybody is setup with a volcano, you can churn out the ABS/rigid variety in a hurry. I found that the retainers need about 30% infill, the mask itself I use zero infill, 4 base layers, 4 top layers, 2 perimeters (with .6mm nozzle). Could probably even step up the layer height further. |
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In case anybody cares, I'm going to turn this endeavor into a website of its own. I purchased the domain "emergency3D.com" I've already had contact with a couple LE agencies and hospital staff, they are interested since there is simply nothing available out there. This is a complete charity thing, but if anybody has contacts (or is) with any agency or orginization, or any individual, the idea is they can simply be pointed to this website for more info. I am hoping to get in touch with the original MD who took lead in designing it, and use it as an example of how not only this mask, but other items like sewn "surgical" masks and 3D printed face shields can be implemented. This is something that not only can hospitals in the US use, but organizations and individuals world-wide. The idea is to have it as a repository of 3D printable or otherwise field-expedient actually effective gear for situations like this. Don't bother looking up the website yet, I just purchased the domain and I'm off to bed. |
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https://emergency3d.com/ Hoping this grows. I would like to get universities and other appropriate organizations on board to test these designs in a laboratory against their commercial counterparts. |
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Anyone try the WYZ TPU from Wal-Mart yet? I'm curious how it prints as I found some very mixed reviews. Was ready to order some, but wanted to see if any of you guys have tried it yet. Side note, I took my PLA+ and decided to try and thermo form it for a better seal. I put it in boiling water for about 15 seconds, pulled it out and let it cool for a second or two them formed it to my face. I can honestly say I now have a 90+% seal, even with my beard. I put a plastic bag in as media and I can pull suction and it won't pull in air from around the mask. It feels almost as good of a seal as my paint respirator from harbor freight. Original right, thermo formed left Attached File |
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I’ve got some N-95’s for my crews. Would anyone be willing to print and sell these to me? I’d prefer to use these and give the masks I have to health care workers. Myself and workers deal with fecal matter so PPE is essential. PM me if you’d be willing to help. I’d happily trade ammo for masks to protect my employees and myself. If not what’s the cheapest easiest to use printer I can buy to print these? |
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Quoted: I've got some N-95's for my crews. Would anyone be willing to print and sell these to me? I'd prefer to use these and give the masks I have to health care workers. Myself and workers deal with fecal matter so PPE is essential. PM me if you'd be willing to help. I'd happily trade ammo for masks to protect my employees and myself. If not what's the cheapest easiest to use printer I can buy to print these? |
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Quoted: We can't sell prints, but you can put in a print request for someone to print some up to donate. There is a sticky in this forum for it. Quoted: Quoted: I've got some N-95's for my crews. Would anyone be willing to print and sell these to me? I'd prefer to use these and give the masks I have to health care workers. Myself and workers deal with fecal matter so PPE is essential. PM me if you'd be willing to help. I'd happily trade ammo for masks to protect my employees and myself. If not what's the cheapest easiest to use printer I can buy to print these? Awesome, thanks for the information! |
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Quoted: This is a great thread and fantastic effort for all those involved. How much does the current design weight, i.e. how much of a spool does it use? |
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made a mod to the retainer; little section on the top to help push the filter media against the mask. I've found that on a TPU mask, if you flex the mask wider, a small gap can form at that area. I have a TPU mask on the printer now, so I won't be trying it out until tonight. I made the gap between the "tab" and the mask at .5mm on the 1mm gap retainer, will see how it does with tight "filters" (2 layers shop towel). Also, I will be picking up some high quality furnace filters that are supposed to reduce bacteria and viruses to try out as filter media tonight. |
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Got my hands on some 3M Ultra Allergen HVAC filters today. They are advertised to reduce bacteria and viruses. I stacked 4 layers thick and put them on a TPU version mask. Nice tight fit with the 2mm gap retainer, and you can breathe through it with absolutely minimal restriction. I'm going on the assumption that its safe to breathe through these filters, as you run them in your house HVAC. |
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New test version now that has a 3M coupler for regular cartridges. Also found a cartridge adapter on GrabCad that lets you use JUST the N95/P95 pre-filter. Just in case you can get some of the 5P71 pre-filters (they are available here and there). Its going to be printing until midnight, so I'll report back tomorrow. |
Polycarbonate. Rated functional to 110C, and likely capable of being autoclaved without problems. Pretty stringy, I had to torch some wisps off. I'm working on the other piece with integrated tabs to help remove it. I also have some TPU rated functional for 100C that I'm gonna test out. |