Clear N95 + Mask , 3d Printed & Vacuum Formed

Covid-19 and Flu, 3d Printed and Vacuum Formed for Cerebral Palsy, Hearing Impaired, Deaf, Autistic and Elderly

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>>The white mask in the picture is a prototype before vacuum forming in clear PETG<<

This is a WILDCARD and UCPLA submission

A Clear Comfortable N95+ mask for for cerebral palsy, hearing impaired, deaf, autistic and eldery. Even childrens hospitals, private doctors, families and care givers benefit from our clear N95+ reusable masks.

Size shown is XL, there will also be L, M, S, XS and Toddler

After Covid-19 became a pandemic I noticed a particular issue with communicating while myself and others where masks. I am hearing impaired and I heavily rely on mouth movement and facial expression to figure out what you are saying.
3D Printed Frame

Vacuum Formed Clear Cover

Replaceable double MERV 13 electrostatic filter

Also glasses and goggle wearing individuals will love this because the edge of the mask stays away from the bridge of the nose.

Please LIKE as this helps the project team get Seed Grants from Hackaday for the Hackaday Prize 2020 Challeng

i. Concept- Is the project creative, original, functional, and pushing boundaries? Does the project effectively address the selected challenge?

YES , Cerebral Palsy Adaptive Technologies, Expression and communication. Our project pushes the boundaries of how we consider PPE to look and be used. Enhanced fitment, functionality and re usability is a valuable feature. Multiple sizes of vacuum bucks allows for a variety of sizes even in children sizes if you will that a standard mask does not fit.

ii. Design- Is there a depth of design detail available (like a system design, CAD models, project test methods, etc.)? Is there base-level planning for the functionality (e.g., functional block diagram, list of specifications and descriptions of how they will be met, etc.)? How user-friendly is the design?

The design is user friendly and light. Simplicity is important for effective duplication and  re usability. Every step of the project has coordinating files saved for them. 

iii. Production- Is the project realistically reproducible (taking into consideration necessary materials, skills, and production processes)? Are the manufacturing processes detailed? Are those processes realistic for scalability?

The Clear View mask was intentionally designed for rapid reproduction in mind. School kids will be going back to school soon and this could be very valuable.

iv. Benchmark- How well is the project impact and viability demonstrated? Are estimated costs realistic? How well does the project improve upon other currently available solutions?

I will make a video showing the parts and how it is produced, as well as a variety of sizes on my family as a example.

v. Communication- How thoroughly have the Final Round requirements been completed? How well documented is the project? How “open” is the design? 

NOT YET, but the project steps are being documented as I go and no doubt will be very thorough.

  • 1 × Please Like and Follow Getting seed grant money means everything to this project!
  • 1 × .04 PETG clear plastic 8 x 10 sheets
  • 1 × 3d printer > for prototyping
  • 2 × Custom Vacuum tables There are two, one for the frame and the second for the clear cover molding
  • 1 × 8 slice Toaster oven Used to warm plastic sheets to prep for molding

View all 7 components

  • Design in production

    Josh Starnes12/07/2021 at 00:25 0 comments

    These are first models I ordered made in China, the clear portion is Polycarbonate and the rest is PETG and Silicon around the edges.

  • Dad sized for a mask

    Josh Starnes07/25/2020 at 03:03 0 comments

  • Vacuum Table for UCPLA use

    Josh Starnes07/19/2020 at 22:48 0 comments

    As anyone knows who is keeping up with the project, the goal here is to get UCPLA resources to make as many of these masks as they need, not just a method of how to do it. Here is their vacuum table to use in their shop.

  • Clear Cover Vacuum Bucks

    Josh Starnes07/18/2020 at 20:30 0 comments

    Okay I sized all the clear cover part bucks to match the sizing frames. Here are the first three bucks of 14. All three will be finished tomorrow and I will get the next three printing.  I am considering leveling some of the new printers and start them up for once. I only have so much time and setting up printers can take a lot of time to dial in especially when there are several printers your working with. In the picture we have 97 percent , 94 percent and 91 percent sizes.

  • My fiancé fitting a mask

    Josh Starnes07/18/2020 at 02:18 0 comments

    She has an abnormally small and short nose, so the padding in the nose has to be a thicker to fill for gap OR I can 3D print a space that glues in. Honestly I like the spacer add in better because this is meant to be a premium fitment solution.

    I plan to take a photo of every person I size for a participation record as well as further improvement to sizing design.

  • My step kid 14 years old sizing a mask

    Josh Starnes07/18/2020 at 02:14 0 comments

    The masks usually fit well enough that they will hang on the face without much effort, but of course they will need straps

  • My Mom tries on a mask

    Josh Starnes07/18/2020 at 01:52 0 comments

    this is the shot where she is telling me not to take a picture because she doesn’t have her makeup on.. lol

  • Sizers done, 1-14

    Josh Starnes07/18/2020 at 01:48 0 comments

  • Fitting a mask for my 6 yr old

    Josh Starnes07/18/2020 at 01:36 0 comments

    it actually fits well enough he can hang it on his face like hanging a spoon or n your nose! Lol well anyways his size is 10 from the top, he cannot wait to have his own now.

    I just printed three more mask sizers for a total of 14 right now.  Originally I planned to go down to 20 sizes but I may stop at 17. The mask frames only take a few hours to print when they are a smaller size.

  • Up to 11 mask sizers stacked

    Josh Starnes07/17/2020 at 22:37 0 comments

    On the printer are likely the last three sizers I will print, because they go down into the 3-4 year old age ranges. I do not think I will go down any further than this.

View all 36 project logs

Enjoy this project?



sirkojac wrote 09/15/2020 at 16:31 point

Any chance of sharing the STL files for the mask? 

  Are you sure? yes | no

Josh Starnes wrote 07/08/2020 at 04:18 point

news flash! - My area of Chattanooga TN ( and soon the whole state) it is now illegal to not wear a mask starting Friday. Also it is said kids will be required to wear them down to 2 years old, only exceptions are when they are eating, at church or home.

  Are you sure? yes | no

Gerben wrote 06/24/2020 at 19:26 point

Adafruit just released a tutorial for a "No-Sew Cotton Face Mask with a Window"

Thought you might like to see it.

  Are you sure? yes | no

Josh Starnes wrote 06/28/2020 at 21:35 point

Whoa that thing is creapy! Thank you for the link.

  Are you sure? yes | no

Simon Merrett wrote 06/15/2020 at 18:17 point

I think this kind of design would help people feel more comfortable wearing a mask in cultures where they aren't commonplace. 

How are you thinking of managing the visible impact of condensed moisture on the inside of the clear cover? 

  Are you sure? yes | no

Josh Starnes wrote 06/16/2020 at 07:37 point

Hello Simon, a hydrophobic anti-fogging coating will prevent moisture from sweat or your breath from causing a fog or droplets on the inside of the mask. Its the same kind of coating on the inside of ski goggles for example. Please Like and Follow! at ton of work is going into something that seems so simple :)

  Are you sure? yes | no

Simon Merrett wrote 06/16/2020 at 07:46 point

I wish you every success with this project. Your plan for moisture sounds like a good idea. Is that coating widely available? 

In the comments on @Jenny List 's article on making a cloth mask one person, whom I can empathise with, had real problems with the exhaust escaping up the junction between the nose and cheek. That's definitely a requirement that a good design should address. 

  Are you sure? yes | no

Josh Starnes wrote 06/16/2020 at 07:52 point

Here is an example, they are common coatings, you can get "permanent" quality ones for glasses, but realistically they physically wear off and need to be reapplied either by cloth or a spray application. So i could combine uvex cleaner and antifog into a small spray bottle for periodic application every few days if used every day and handled often.

  Are you sure? yes | no

Josh Starnes wrote 06/09/2020 at 22:26 point

That's right, there is a serious anxiety factor too. People are less comfortable when they cannot see your face. Special Needs individuals have a very hard time with this.

  Are you sure? yes | no

Dan Maloney wrote 06/09/2020 at 17:10 point

It's a good point. Wearing a mask in public regularly gives you a new respect for how much information we convey just with our facial posture. When you can't smile at someone it's hard to make sure your intentions are clear.

  Are you sure? yes | no

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