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

  • We need an oven to warm plastic

    Josh Starnes3 days ago 0 comments

    Ordered ! Ill show it to you unboxed. It says it is 12 inches deep so that should work, if not I will cut a slot in the back of the oven. After all I will never use this thing for cooking after heating plastic in it a few times. I will get pics of the actual oven and any mods I do to it to be more suitable.

  • No 20 piece sizing kit from adults to toddlers

    Josh Starnes4 days ago 0 comments

    I took some time to scale down the mask for myself , 3 percent for each size until I had 20 mask sizes. I believe I will name the largest No 20 and smallest No 1 , if a larger size is needed later I would simply call it No 21 for example. If by some weird situation someone wants a new born sized mask, I suppose it could be called a Neg No 1 ,  or No 0 , Neg No 2 ext.  Looking at the options I don't think it will be an issue though.

  • New Needs in the community

    Josh Starnes4 days ago 0 comments

    In my city ,county And soon to be state it is illegal to not wear a mask with the exception of being in your home , church and eating.  Also Children will all be required to wear masks at school. I have had many requests for me to make locals masks that are durable and can be washed and reused. Some people like the cloth masks but others don’t like things directly against their nose and mount which is a problem my design works to resolve with shape , form and function.

    I will already me making masks as soon as I can for my family and I will post pictures. I will contact Hackaday and ask if I would be disqualified by making these masks for people in my community. Thank you everyone for your support.

  • Third Vacuum Bed Arrives 12”

    Josh Starnes07/02/2020 at 23:59 0 comments

    here is the 8 x10 Vacuum formIng bed on the left with the clear cover vacuum buck mold. On the right is the one I just received. This is the 12” x 12” vacuum forming bed with the face mask frame buck mold.

  • Vacuum Bed Snag , Ordering a 12” bed

    Josh Starnes06/23/2020 at 00:37 0 comments

    after I tested out the frame buck on the bed it was a little small. The 8 x 10 bed however is fine for just vacuum molding the clear section of the mask which was originally intended.  So it looks like I will have a dedicated buck and table for each part which is not a bad idea when your trying to mass produce these things. This next table ordered for me as a Fathers Day present is a 12 x 12 table.

    This is the second table I custom ordered from Pedro Shop. surprisingly this is a very common day to make vacuum parts, the table is normally wood with a pegboard top , but Predros are very good quality for the price he charges to build them. 

  • FAIL- Printing the Frame buck

    Josh Starnes06/23/2020 at 00:26 0 comments

    two times in a day I had a filament snag, it happens  :/

    twice I had a filament role get snagged twice causing the print to fail. It was still moving , but printing air.  I cannot complain this is the first of 40 roles from this brand to do this. I will need to use a drill and unwind and rewind it tightly again. 

  • Mom try’s on a mask prototype

    Josh Starnes06/19/2020 at 07:57 0 comments

    i think she needs a size or two smaller to be just right , but the says she likes the fitment the way it is.

  • The First Face Seal using Silicon D Foam

    Josh Starnes06/18/2020 at 01:15 0 comments

    I might consider extending the  under jaw of the mask so that it as fit the width of a double D seal as well, however the fitment seems good right now, so we will not make any changes. Even opening your mouth completely like your surprised still pressed against your skin. One way to offer personal adjustment is to offer different thicknesses in D seal so that the user can try it out and make adjustments when needed. The double sided tape holds the seal secure but whenever it wears out, it can be peeled away and replaced at any time. 

    Please take the time to give this project a like, I would really like it to become a real product I can get into the hands of people who need it as soon as possible. Thank You!

    Please take the time to give this project a like, I would really like it to become a real product I can get into the hands of people who need it as soon as possible. Thank You!

    9mm thick on each side of the nose does a good job of creating a comfortable seal

    Please take the time to give this project a like, I would really like it to become a real product I can get into the hands of people who need it as soon as possible. Thank You!

  • Evaluating the MERV 13 Filter Cloth we received.

    Josh Starnes06/17/2020 at 22:15 0 comments

    The filter element brings to entire purpose to the project so this means a great deal that we get it right. We ordered MERV 13 electrostatic medical grade filter cloth from a medical supplier. This is rated for .3 micron filtration through just one layer of the material. We plan to double up the material and zigzag it as well.

    Two MERV 13 cloth strips on top of each other

    You can see the frame is about 5mm thick and here is the doubled cloth in comparison for thickness. As you can see the cloth is very thick once it is doubled up.

    There is a huge buzz about checking your filters by holding them to a very bright light and see if you can see pin holes. These pin holes would be places air can leak through without being filtered. Ad you can see we have NO pin holes, only an even opaque glow.  This is two sheets stacked like pictured above.

  • Clear Piece Vacuum Forming Buck off the printer .1mm Resolution

    Josh Starnes06/17/2020 at 22:03 0 comments

    This buck is fresh off the printer, I did another test fit and things are looking good. I went ahead and started the printer for the frame buck which we will not see for a couple days because .1mm printing is SO SLOW , but the results are desirable.  Once the plastic is stretched it will be .02" maybe less so the fitment between the clear part of the mask and frame should be tight.

    Please take the time to LIKE this post or project, it means everything to seeing this project through to an actual usable product AND winning a position in the Hackaday Challange for a Seed Money Grant.

    Here you see the Buck for the inside by the outer frame.

    Please take the time to LIKE this post or project, it means everything to seeing this project through to an actual usable product AND winning a position in the Hackaday Challange for a Seed Money Grant.

    Please take the time to LIKE this post or project, it means everything to seeing this project through to an actual usable product AND winning a position in the Hackaday Challange for a Seed Money Grant.

View all 23 project logs

Enjoy this project?



Josh Starnes wrote 4 days ago 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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