Across the country, design communities have mobilized to assist in the effort to fill supply gaps in Personal Protective Equipment (PPE) for healthcare workers operating on the front lines of the coronavirus pandemic.
Last week, Archinect reported on efforts at Princeton, Cornell, and Columbia that are coming together to 3D-print visors and face shield harnesses, fabricate hospital gowns, and manufacture other PPE to serve the region’s hospitals.
On the west coast, a project inspired by a call to arms from Cornell University Professor Jenny Sabin has sprung up around the University of Southern California (USC). There, multiple campus entities, including the USC School of Architecture, the USC Viterbi School of Engineering, the USC Iovine Young Academy, and the USC Keck School of Medicine are working to create PPE face masks that come close to meeting N95 standards.
Using a regional network of 3D-printers scattered at participating architecture firms and universities, including University of California, Los Angeles (UCLA), Southern California Institute of Architecture (SCI-Arc), and Cal Poly’s LA Metro program, the #OperationPPE effort is fabricating protective gear that could prove pivotal to fighting the virus if existing stocks are depleted and medical workers have to resort to improvised means of protection.
USC Professor Alvin Huang explains: “This is what Keck [School of Medicine] has identified as ‘wartime medicine,’ so we are working on the back-ups to the back-ups.”
Working from home offices, school print shops, and firm fabrication facilities, the group has coordinated file sharing and manufacturing initiatives to optimize and perfect the 3D printing files for a N95-like mask meant for last-resort use. The 3D-printed components are designed to snap together and require the addition of a HEPA filter insert and perimeter sealant to properly function. The masks are “are a step above using handmade masks and bandanas,” Huang writes.
The effort was recently endorsed by Los Angeles Mayor Eric Garcetti, who in a recent COVID-19 related televised update announced the City’s support for the #OperationPPE initiative.
In the talk, Garcetti said, “I’m proud to announce we’re mobilizing our architecture, design, and manufacturing communities to utilize 3D-printing technologies” to aid in the response. Garcetti added that the city was “working with local universities, design schools, and architecture firms to utilize their materials and expertise.”
Huang tells Archinect that the USC team has support from Gruen Associates, AIA California, and AIALA, which are now providing USC’s printing teams with material, including 60 additional spools of PLA, the plastic filament being used to fabricate the masks. Huang adds: “We are, however, having difficulty finding sheets of .02"-thick PETG for the face shields, but are trying to source that now.”
In addition to Gruen, the effort has received support from a variety of local architecture firms, including: KAA Associates, ARUP, CO Architects, Michael Maltzan Architecture, Brooks + Scarpa, ECM Interactive, HNTB, IBI Group, HGA, KoningEizenberg, Lorcan O’Herlihy Architects, Tighe Architecture, and Huang’s own firm, Synthesis Design + Architecture.
Huang writes, “Our group is now up to 130+ people with 105+ printers, 3 lasercutters, and 215+ spools of filament.” Huang explains that over 80 students are involved in the project.
The designers have published a sign-up sheet for those interested in contributing to the effort. The link includes access to the Keck School of Medicine-approved .stl files that can be used to print the mask components.
9 Comments
thank you Archinect, I literally have the exact same printer at home (took it from office just in case), was trying to find the right stuff and data to print, looks like Alvin did the leg work here.
any reason why no ABS?
reason I ask is ABS I believe can withstand higher temperatures vs PLA, although it appears PTEG is preferred.
think I am going down this path for my area - https://blog.prusaprinters.org/from-design-to-mass-3d-printing-of-medical-shields-in-three-days/
The 3D printed masks also require a HEPA filter insert, as well as a perimeter gasket to seal against the face (we are using off the shelf weatherstripping). PLA, PETG, and TPE are the approved materials. ABS is toxic and cannot be used.
All of our files have been tested and approved by Keck Medicine. They are not however, replacements for proper N95's or true medical gear. They are backups to the backups, and are being produced to keep our medical professionals on the front lines from having to use handmade fabric masks, bandanas and socks. Literally. All of our files are available to download here: https://bit.ly/OperationPPE
FAQs on 3D Printing of Medical Devices, Accessories, Components, and Parts During the COVID-19 Pandemic [from the FDA]
I don't know much about 3D fabrication, so I am just wondering if the 3D printed masks are flexible enough? Because I think the material should be flexible enough to better fit to different face shapes/sizes for better protection/seal. The problem of face seal is also why workers need to get an N95 fit test to find the right n95 model fit.
Anyways good to see the work and progress
The masks require a flexible rubber gasket at the perimeter to seal against the face (not shown in the image above, but included in our instructions when you download the file).
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