Flexible Mask Rolley [ Universal Modular System ] Covid-19

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Yet another easy printable and usable mask. The shape of this design will cover your chin. Design inspired by an antique TLR. First prototype equip with two extended hooks for strap which looks like the aperture and shuttle dials. Now is a bit too sci-fi.

(Updated 17-Apr-2020: Added 3M and Moldex filter cartridge support)
Please always check for update before you do the next print.

[ Breathing Valves | Print time 2.25hrs | inout Filter | 22g | 7-sizes | Remix Template | Future Module Upgrade ]

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(---- Notice ----)

Why will I not design this mask for printing in PLA or PETG?!

I get quite a few requests to convert this design for printing in PLA or PETG. Sorry, but I am not going to do that, and this is why:
In my experience, PLA and PETG are TOO DANGEROUS to put on your face. If a PLA or PETG mask cracks, especially when printed as a light weight/thin wall, it will cut your face like a knife. It may not be happen on the first day, but it will happen one day, maybe while you are talking, and it will be sudden. Thin walled PLA and PETG will fatigue much faster than TPU, being washed, dragged and pulled in daily use. Maybe something hits your mask while you are wearing it, and it splits or shatters.

Let's see poor Kevin in the following videos:
For Part 1 in PLA please go here: https://youtu.be/ErP28uP4mVI
For Part 2 in PLA please go here: https://youtu.be/LlN01EW9ORI
For Part 3 in ABS please go here : https://youtu.be/feWsPd2XUFU
For Part 4 in PET-G please go here : https://youtu.be/k-KhRx73NxU

That is why I don't want to convert this design to use PLA/PETG. It is for your safety.

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Please be respectful, print it and make it well before making adverse comments. Don't make any judgements based only on skimming around.

(--- DISCLAIMER ---)
Print and use it at your own risk.

Uses up to 10mm thickness Filter. Mask weight 22gram.

Key features of this design include:
-Separate inlet and outlet valves prolong the lifespan of the intake filter.
(humidity of exhaled breath always shorten the filter life)
-By design the flexible mask will fit on any face. (Or use hairdryer and scissor for best fitting)
-100% infill so no hollow structure,
-Modular System for future extension.
-Remix template for makers

Only ever use filters you trust. Wash the mask in soapy water for 20 seconds or more when you remove it. Remember that if the filter has protected you against COVID-19, then the virus is now on the outside of the mask or in the filter media, and it can still contaminate you unless/until you kill it first, in soapy water. All in all, I believe your satisfaction with this mask should be limited only by the skill with which you make it, and not by any features of the design.

Hope I won’t see any more comments to this design base on general 3d print issues(rough surface, hollow structure, etc).

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HEPA filter mount STL and customizable scad here.

I made this for the community, to help meet a need during the shortage of surgical masks, due to the outbreak of the Covid-19 virus.

Read my PROFILE page if you want to redistribute my design materials to others, for free or commercially.

Good Luck everyone and my love.

Do subscribe to my YouTube channel. Stay tuned on the latest build videos.

All constructive comments and suggestions are welcome.

Tip me a cheese burger and subscribe my YouTube Channel if you like to support my work.
https://paypal.me/iczfirz
https://www.youtube.com/c/iczfirz

Assemble Animation

Loose sew two discs. Snap on all parts together. (To seal with glue or not? It’s always depends on the makers' handcraft but it is not necessary by design.)

Addiction to 3D Printing? Watch these time-lapse!
https://youtu.be/-ZsXFX6hjXk

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https://youtu.be/L4IDmn3miE0

https://youtu.be/y3-0Y90HoYo
 

Need a Goggles, please check https://www.thingiverse.com/thing:4317517
 

If you have 3M Half Facepiece, please check https://www.thingiverse.com/thing:4264152
 

If you have Ambu Mask / BVM, please check https://www.thingiverse.com/thing:4260234
 

Looking for a 3D-printable air purifier device? Here you go >> [Deckman]

Print Settings

Printer:

Bed Size 120 and up

Rafts:

No

Supports:

No

Resolution:

0.1-0.3mm

Infill:

100%

Filament: Any TPU + {PET-G / PLA} Any
Notes:

A good 3dp maker should always:-

-Measure the weight of printout to know if under extrusion or not. It should be same as the slicer reported total material used weight.

-Always push but not pull to avoid layer separation when assembly.

-Always check for update before you do the next print.

As of now 6 types of bodies , many types of modules

-A_Shape type use A_Shape modules, O_Shape type use O_Shape modules.(Recommend O)

-Outlet valve on A_Shape is relatively small so it is not suitable to put filter in the outlet(Won't protect other)

-3M modules can accept 3M 6000 or 7000 series filter cartridge. (You can print your own cartridge. Check my Hepa design)

-Hex modules accpet bigger filter but tradeoff the valvy. Good for kids and oldies if they can't handle the valvy system.

-Moldex modules for Moldex filter cartridge. (Yet proof. Please report if any error.)

Slicer Concern on body stl

Body contains overhang structure on the snap ring. It doesn't need support and it will be fine with 0.3mm layer height and 0.4mm nozzle diameter.

Body wall thinkness is 0.8mm, which is 2x of the 0.4mm nozzle diameter. A good slice will give you exact 2 rounds of TPU with minimal to no travel at all. Check photo below:

Cura Common for all STL

-100% infill

-Initial layer height = 0.2mm

-Initial layer bed temp = 50degC, else layers bed temp = OFF.

-Support = "Off" (Tiny overhang but should be fine)

-Seam Corner Preference = "None"

-Layer Start X Y need to be middle and below the print object - 6 o'clock (eg. If you bed 300*300, Lower Left X,Y is 0,0 , then set Start X=150, Start Y=0, preview to see nozzle always start at the the bottom of the object. Sample gcode uploaded FlexibeMaskRolley_M_TPU.gcode )

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Part 1

Use TPU. Mirror at Z to put the snap ring on bed. Layer Height 0.3mm (don't try to lower), may need slow speed for those layers below then 4mm (due to overhang).

-Choose one of the following size to print.

-FlexibeMaskRolley_XL_TPU.stl

-FlexibeMaskRolley_L_TPU.stl

-FlexibeMaskRolley_M_TPU.stl (Start with this size for fitting)

-FlexibeMaskRolley_S_TPU.stl

-FlexibeMaskRolley_XS_TPU.stl
Assume Body STL place at the center of print bed.

Setup new Cura Profile

Material

-Generic TPU 95A (reminder. Cura default extruder setup is 2.86mm. You may need to set it to 1.75mm.)

Print Settings (Setup new Profile base on stock Extra Fast 0.3mm base profile)

-Custom

Profile

-Extra Fast -0.3mm

Layer Height

-0.3mm

Initial Layer Height

-0.2mm

Wall Thickness

-1.2mm

Fill Gaps Between Walls

-Nowhere

Seam Corner Preference

-None

Infill Density

-100%

Build Plate Temperature

-20degC

Build Plate Temperature Initial Layer

-50degC

Layer Start X

-0 (delta), or

-Max X size / 2 (Rectangle bed. Lower Left as origin)

Layer Start Y

-0 (delta), or

-0 (Rectangle bed. Lower Left as origin)

Skirt Line Count

-3

**Fine tune retraction (I use 5mm) speed (I use 60mm/s) and extra prime (I use 0mm) for your extruder and TPU.

Preview slice result. Follow the check list below:

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Part 2

-Print Thin Walls = "ON"

-Fill Gaps Between Walls = "Everywhere"

Use PET-G/PLA. Layer Height <= 0.3mm,

-FlexibeMaskRolley_Front_PLA.stl

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Part 3

-Use TPU.

-Print Thin Walls = "ON"

-Fill Gaps Between Walls = "Everywhere"

-Layer Height <= 0.3mm, Print Sequence = "One at a Time"

-FlexibeMaskRolley_In_Cover_TPU.stl

-FlexibeMaskRolley_Out_Cover_TPU.stl

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Part 4

Use TPU. Layer Height <= 0.1mm(initial layer 0.2mm), Print Sequence = "One at a Time"

-FlexibeMaskRolley_In_Disc_TPU.stl

-FlexibeMaskRolley_Out_Disc_TPU.stl

(You may loose sew the discs or resize the disc to fit your breathing rate.)

(FlexibeMaskRolley_Out_Gasket_TPU_Optional.stl only if you get too rough surface on the outlet valve area)

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Part 5 (Optional - You may use your own stripes)

Use TPU. Layer Height <= 0.1mm(initial layer 0.2mm), Print Sequence = "One at a Time"

-FlexibeMaskRolley_Stripe_A.stl x2

-FlexibeMaskRolley_Stripe_B.stl

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It also share the same stripe set from https://www.thingiverse.com/thing:4177128.
If it is just slightly not long enough, you can always hairdryer heat it to extend the length.

Although 3M Module consist 3 lugs overhang structure, make sure fan is on and they will be fine. You will need to trim and smooth the lower part of the lugs.

If you are looking for bigger breathing valves, you may choose the SIO (Same Inlet Outlet Size), or use the Extra SMALL ( FlexibeMaskRolley_XS_TPU.stl ) then scale up all the stl parts in X, Y, and/or Z together. So you have all valves size increased.

May try the HEPA for Valvy in my Thingiverse design profile page. So you can make your own HEPA cartridge. (Make use the Shift and Slope to make more clearance to intake)

Modular Remix Template for Further Development.

Welcome for Remix

-FlexibeMaskRolley_Remix_Template.stl

-FlexibeMaskRolley_SIO_Remix_Template.stl

Assemble Video

Category: DIY