With masks in short supply, BYU engineers use 3D printing labs to assist first responders

When local police asked for help 3D printing masks, BYU's engineering labs responded and began printing masks nonstop in labs usually occupied by students. The reusable masks (based on a blueprint that was provided) have a unique design which requires only a small square of protective N95 material. The 3D mask design itself was created by neurosurgeon Dusty Richardson of Billings Clinic. Anyone who would like to assist by printing 3D masks can download the blueprint at provopolice.com.
Additional information about 3D printing projects for first responders: 3dprinting.byu....
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Writer: Natalie Ipson
In a corner lab of the BYU Crabtree Technology Building, there is a constant hum as five machines zip back and forth. Hour by hour and layer by layer, a group of 3D printers are churning out protective face masks.
A few days prior, Provo City Police and Provo City Fire sent out a call for help. As is the case for many first responders across the nation, the coronavirus pandemic has caused a shortage of personal protective equipment (PPE).
Provo City Police tracked down a blueprint for a reusable respirator mask that could be created on a 3D printer and asked anyone with a 3D printer to power up their machines.
“When we got the call from the police, we jumped on it and made it our top priority,” said Therin Garrett, operations manager of the BYU Prototyping Manufacturing Lab.
BYU's Ira A. Fulton College of Engineering has at least 18 printers available between its manufacturing engineering and mechanical engineering laboratories and the prototyping manufacturing lab to produce the new masks. Garrett has been coordinating between laboratories to get a new batch of printers running each day.
And the engineering department isn't alone in its efforts - BYU's Physics and Astronomy department has another eight printers churning out masks, and several students have donated their personal machines to the cause, producing one mask every eight hours from their apartment bedrooms.
“We all have a responsibility to help where we can," said Michael Jensen, dean of the Ira A. Fulton College of Engineering. "To be able to dedicate our resources and skills to help, even in a small way, those on the front lines who are navigating this crisis gives additional meaning to what we do.”
Designed by Montana doctor Dusty Richardson, the purpose of this specific mask is two-fold:
Reusable: Each mask is customizable to the wearer’s face (similar to a sports mouthguard that you’d mold using hot water) and can be sterilized for reuse day after day.
Stretching Resources: The mask isn’t a replacement for the scarce N95 masks, but first responders can cut up one N95 mask to fit over the filter of the 3D printed mask. A single N95 mask can supply up to five 3D printed respirator masks.
The cost of materials per mask is a small $1.38, but as with most 3D printing, Garrett has to balance speed with quality. It takes roughly three hours for one printer to make a single mask, anything faster and the mask will have defects. Some of BYU’s printers can create three masks at once in about nine hours.
The 3D printed masks are not FDA approved replacements for true N95 medical-grade masks, and will require first responders to do some training on the proper application of the mask.
This particular job hits close to home for Garrett. For the last four years, Garrett has served as a volunteer Firefighter and EMT for Mapleton City. Each day after work at BYU he gets to see firsthand just how scarce protective resources are for first responders.
“I was taking patients to the ER last night, dressed in full protective gear,” Garrett said. “It’s exciting to see the engineering side and the first responder side of this come together. It gives me hope that this might actually work to help save resources and even lives.”
Garrett also cautioned that the 3D printed masks are not FDA approved replacements for true N95 medical-grade masks. The 3D printed masks will require first responders to do some training on the proper application of the mast.
Student lab manager Jason Redding is from the greater Seattle area and his parents still live in a suburb that saw some of the country's first cases of community spread of COVID-19. Redding said he's grateful for any chance to contribute to slow the spread of the disease.
Anyone who would like to be involved in the project can download the blueprint at provopolice.com.

[@libbybaker6369]

Bravo!! This shows ingenuity, dedication and humanitarian concern for their fellow persons. My daughter is a first responder, and I hope she is able to get one of their masks. She lives in Michigan, where supplies like these are in short supply.

[@barbaravance6774]

Very cool! I was thinking about trying this at our home. I am a post transplant patient and living minus several organs. So going out for food etc...is a very risky business. Thank You for all you are doing. My Sister-in-law works at Children's Hospital in the ER. And the lack of PPE is horrible. And she is terrified for her patients as well is family at home. She cares for my Mother-in-law who has M.S.. Exposure is on everyone's mind. I believe projects like yours is the answer. Good Luck! And God bless you. 🙏

[@kelticsoul]

It's terrific when science and creative minds come together to make such a responsive and greatly needed tool at this difficult time. Thank you for sharing your ingenuity and resourcefulness in this unique way. DOWNRIGHT AMAZING!

[@Caleb_Guffey]

When BYU uses prusa yes still uses cura as a slicer

[@robertzeman4301]

I think you can also use Hepa filter from vacuum cleaners.

[@kiddfpv]

Also can you post a video about how to form fit them with hot water?

[@truantray]

I've printed those exact masks, they take 19-21hrs each. In that time, injection molding could make > 1,000. The best filament for air seal in flexible TPU. The hot water PLA fit helps, but doesn't seal well if wearer tries to talk.
Also, a study was published this week that concludes N95 is only required when inserting breathing tubes.

[@LT72884]

Even at good settings, it only takes 3 hours for me. But i have now remixed the mask to print in 2.

[@Vladlabs]

great job!

[@leucanhnguyen6695]

This vid is cool, and im impressed by your idea. AMAZING!!!

[@Joe_Public]

What kind of 3d Printer are you using?

[@xscitobor1233]

The orange 3D Printer in the video Is a very good and reliable printer called "Original Prusa i3 mk3" and the other one the "BlackBelt" is special type of printer that has an "infinite Z" coordinate capability's .

[@taraedwards341]

That is so awesome. Can you share your .stl file or G code?

[@BYU]

This link might be helpful: 3dprinting.byu.edu/covid-19/

[@kiddfpv]

Can you post the link to the file? I’d like to print some for my family and coworkers

[@BYU]

This link might be helpful: 3dprinting.byu.edu/covid-19/

[@aim6mac]

hi there, nice vid. can you share the STL file of the mask? thanks in advance!

[@BYU]

This link might be helpful: 3dprinting.byu.edu/covid-19/

[@dehurt]

Check out the designs on 3dprint.nih.gov