Stopgap Surgical Face Mask (SFM)
This model has been superseded by Stopgap Surgical Face Mask revision B, which was designed to increase comfort. This version may still be used, but see the revision B link for improvements.
This item should only be manufactured in a current Good Manufacturing Practices (cGMP) facility. If this is not manufactured in a cGMP facility under an appropriate quality management system, it should not be used in a clinical setting.
This mask should only be printed with Multi-Jet Fusion (MJF) or Selective Laser Scintering (SLS) technologies out of powder-bed nylon
*** See the Documentation tab for detailed information including the Instructions For Use, Manufacturing Instructions, Bill of Materials, and Test Report ***
This device has not been tested to assess the out-gassing limits of the material or their corresponding health effects.
*** Updates coming ***
We also hope to release at least one other size soon, and expand our filter and cleaning options. Please check this site frequently for updates.
SolidWorks files attached - see Download button
Bill of Materials added to Documentation tab
Manufacturing guidance updated added to Documentation tab
Small size added. Now both small and medium available.
******
The Stopgap Face Mask was created as an emergency action in effort to protect people by providing backup PPE options if the standard PPE has become unavailable. This device has not gone through the same regulatory approval process as standard PPE.
The Stopgap Face Mask consists of two main components (the mask body and the filter cover) and contains features for attaching two elastic straps and receiving a patch of filter material. It is recommended that the rectangular filter patch and elastic straps are disposed of after every use of this device. The remaining parts of the plastic mask can be disinfected using common disinfecting solutions or sterilized and reused.
Many people contributed to this project and we thank them for their dedication and support:
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- Patrick Aubin (Veterans Health Administration)
- Jared Bliss (Veterans Health Administration)
- Brian Burkhardt (Veterans Health Administration)
- Stuart Fairhurst (Veterans Health Administration)
- Joseph Iaquinto (Veterans Health Administration)
- Eli Kaufman (Veterans Health Administration)
- Matt Kindig (Veterans Health Administration)
- William Ledoux (Veterans Health Administration)
- Steve Morin (Veterans Health Administration)
- William Nylander (Veterans Health Administration)
- Chris Richburg (Veterans Health Administration)
- Beth Ripley (Veterans Health Administration)
- Brian Strzelecki (Veterans Health Administration)
- Greg Voss (Veterans Health Administration)
- Matthew Di Prima (Food and Drug Administration)
- James Coburn (Food and Drug Administration)
- Anthony Anderson (University of Washington)
- Lynda Brady (University of Washington)
- Colleen Carroll (University of Washington)
- Alex Hotz (University of Washington)
- Mark Ganter (University of Washington)
- Ian Good (University of Washington)
- Liang He (University of Washington)
- Dalton Hildreth (University of Washington)
- Yuri Hudak (University of Washington)
- William Lack (University of Washington)
- Jing-Sheng Li (University of Washington)
- Dmitry Levin (University of Washington)
- Jeffrey Lipton (University of Washington)
- Kelly Mack (University of Washington)
- Jen Mankoff (University of Washington)
- Connor Mulcahy (University of Washington)
- Alshakim Nelson PHD (University of Washington)
- Monica Ortiz (University of Washington)
- Jonathan Posner (University of Washington)
- Annie Ross (University of Washington)
- Anastasia Schaadhardt (University of Washington)
- Adriana Schultz (University of Washington)
- Anne Turner (University of Washington)
- Megan Hofmann (Carnegie Mellon)
- Scott Hudson (Carnegie Mellon)
- Jim McCann(Carnegie Mellon)
- Aidan Fay (Stanford University)
- Elizabeth Foster (3D Systems Healthcare)
- Benjamin Johnson (3D Systems Healthcare)
- Shelby Marks (3D Systems Healthcare)
- Jacob Ames (Hawk Ridge Systems)
- Brandon Boulden (Hawk Ridge Systems)
- Tristan Butler (Hawk Ridge Systems)
- Mark Dolinar (Hawk Ridge Systems)
- Matthew Fisher (Hawk Ridge Systems)
- Devin Johnson (Hawk Ridge Systems)
- Jack Aubin
- Kavi Dey
- Caitilynn Larmore
- Kelly Richburg
- Sherry Sellentin (Pacific Fabrics and Crafts)
- Kathie Varney (Pacific Fabrics and Crafts)
- Karen Grosh (Pacific Fabrics and Crafts)
Comments
nicholas.cavaliere
Sat, 2020-04-04 13:33
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Raw file request
We're looking to mass produce the mask if possible. Creo doesn't play nicely with STL files. Do you have the raw IGES, STEP, or Creo .prt files for this mask by any chance?
Chris Richburg
Sat, 2020-04-04 17:04
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raw files
Nicholas, we are working on releasing parametric SolidWorks files. Please check this page for updates.
tdecarmine
Wed, 2020-04-15 13:17
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Solidworks release
Is there any word on releasing the vector CAD files for this (or other) designs? We are looking to use a higher performing material (OXPEKK) that is steam sterlizable (everyone has an autoclave, eh?). Further, we see other forming methods that could be made to work but ~need~ the origin file. Thanks and Great Work, All.
pmcgarr
Mon, 2020-04-06 11:47
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CAD Files
Hi, we too would benefit from parametric CAD files. I posted a request earlier and it disappeared, possibly in moderation. I'm replying here in case my previous post did not go through. We use Solidworks, but could also use STEP or other solid (not mesh) model format.
Gustavo Chaves
Sat, 2020-04-04 18:48
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I want to print
Hi, I am buying a 3D printer to help. I am buying a "Flsun QQ" model. Will it work? I´ve chosen this model because when corona is over, I will help people that need prosthetic legs (this printer can print high objects, such as prosthetic legs).
Also on this mask print, what´s used as the filter>
Thanks.
Best regards,
nicholas.cavaliere
Sun, 2020-04-05 09:09
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Raw Format
Chris, understand you guys are extremely busy and I fully appreciate your work! They don't need to be perfect though, even a STP is fine, just something I can extract surfaces from and run toolpaths off of. We need to modify slightly anyway for the method(s) of production we're considering. Feel free to email me at this alias at navy.mil if that's easiest.
-Nick
jrhirsch
Sun, 2020-04-05 17:17
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FDM revised mask
For FDM printing [filament type] the mask needs to be modified. The overhangs cant be printed without supports. which will greatly increase print time. Most other mask designs can be printed without supports.
The portion on the mask where the filter rests needs to be flat to the surface its printed on. Otherwise it will be too rough a finish and not hygenic. If you add supports it will take longer to print and the sealing surface might still be too rough. I think nylon will be too stiff and not conform to the wearers face. TPU might be better a better choice.
nickjgates
Fri, 2020-04-10 13:19
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Successful FDM Print
I reoriented the design and added supports. I can report a sucessful print on my Prusa i3 MK3. gcode here: https://3dprint.nih.gov/builds/nickjgates/stopgap-surgical-facemask-pla
residude
Sun, 2020-04-05 23:15
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Would PETG or TPU work? How about acrylic spray coating?
Hello,
I have 4 Creality CR10s Pro printers and I think I can print lots of masks. I noticed PLA is not good, what about PETG or TPU? If nylon is a must, can we use something like this?
https://www.amazon.com/eSUN-1-75mm-Printer-Filament-Natural/dp/B00PJIA90O/ref=sr_1_3?dchild=1&keywords=nylon+filament&qid=1586141931&sr=8-3
Also we have many acrylic coating and plastidip coating like this:
https://www.amazon.com/gp/product/B00E975M8A/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1
Please make a list of printer materials, from what we read in online forums hospitals and doctors desperately in need of mask in some locations.
Regards
Tudorprinter
Mon, 2020-04-06 06:04
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Why not use industrial filter and cut it up
I was wondering why one could not use this type of industrial filter which is F8 so stops 90% of 0.4micron particles such as this one https://uk.rs-online.com/web/p/hvac-air-filters/8279712/ I am sure that there is a US equivalent
Tudorprinter
Mon, 2020-04-06 06:39
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Filter suggestion
Is there a reason not to use an industrial filter such as this one? https://uk.rs-online.com/web/p/hvac-air-filters/8279712/ It is almost N95 equivalent and surely better than cutting up a surgical mask?
MatrixLlama
Mon, 2020-04-06 07:58
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Succesful Nylon print on FDM printer
Thank you for posting this design. I succesfully printed it on an FDM printer. If some of the overhangs of greater than 45 degrees could be eliminated though, it would be faster and easier to print. (The strap attachment points and the lip where it contacts your face could have a 45 degree blend on the underside.)
combosolo
Mon, 2020-04-06 10:39
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Hi, Can you help to share
Hi, Can you help to share solidworks file?
pmcgarr
Mon, 2020-04-06 10:47
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Parametric CAD Files
Hi,
Thank you for sharing this project. Saturday you indicated you were working on sharing Solidworks files. Can you update us on that? Please, if there is any way you can share these files, it would be very helpful. Personally I would like to remix this design to accept filters that were designed for a respirator. There are many designs out there, but the testing you are putting into fitment is reassuring to me to use as a starting point. I will gladly share my work.
combosolo
Mon, 2020-04-06 10:56
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Solidworks file
Hello,
Can you help to share solidworks file?
chrisf
Mon, 2020-04-06 11:06
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Too much overhang for typical FDM 3d printing
Chris Richburg, I'd like to get the original Fusion 360 file for this design if possible. As others have noted, this design apparently isn't intended for just anyone with a 3d printer to print. Most relatively inexpensive 3d printers from Prusa, Ultimaker or Lulzbot use Fused Deposition Modeling (FDM). This design is intended for a different type of Powder Bed Fusion printing. I tried the model in Cura and it requires lots of overhang and said it would take over 10 hours to print one. I'm considering a similar design for FDM that would the same filter box and a similar profile against the face but require minimal overhang, reducing material required and print time with FDM methods. That would allow for the same filter to be used in either model. I'm not sure about sterilization techniques for anything that is printed with FDM but maybe someone else can consider that issue. It appears that some face shield bands have been recommended that can be printed with FDM so I'd guess that issue has been addressed.
wjonakin
Mon, 2020-04-06 16:56
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Agree - not practical for FDM
Tried a couple times, but required lots of supports, lots of time, and the amount of material that would be thrown away (recycled) with each build would be prohibitive.
CustomColor3D
Mon, 2020-04-06 13:45
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MJF
Do you have the SSP with an optimized build for the 580? We have the capacity to crank a lot of these out if there is an order for them. We're currently manufacturing at our base cost and donating labor and machine time. We can also vapor smooth these to increase their ability to be disinfected and cleaned.
ahotz
Wed, 2020-04-08 14:38
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Optimized .ssp Build Files
Thanks for your question,
We don't currently have an optimized build .ssp file. However, we recommend following the manufacturing guidance for MJF found in the 'Extras' tab to start and optimizing the part nesting from there. We were able to fit 16 masks in one build for the MJF 580 by stacking the masks horizontally while also printing an equivalent number of fiter covers, however this number may be able to be optimized further.
Andrew Pho
Mon, 2020-04-06 14:41
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Injection Molding
Hi Chris,
I only have FDM printers but I have access to injection molding machines. What are your thoughts on injection molding these masks? What is your current print time per mask?
Thanks,
Andrew
Andrew Pho
Mon, 2020-04-06 14:45
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Injection Molding
Hi Chris,
I only have FDM printers but I have access to injection molding machines. What are your thoughts on injection molding these masks? What is your current print time per mask?
Thanks,
Andrew
foltz61
Mon, 2020-04-06 15:25
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Printed this on my SLA resin
Printed this on my SLA resin printer but it failed. What was left was too thin and brittle to get off of the build plate without breaking it.
JJBell237
Tue, 2020-04-07 00:03
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Tracking Downloads
This might be more of a question for admins, but is there any way to track the number of people that downloaded, and implimented your design?
Meghan McCarthy
Wed, 2020-04-15 17:38
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Coming back soon
This feature had to be removed awhile back but it is on our current to-do list. Thanks for asking!
3D Printing Tech
Tue, 2020-04-07 04:44
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SLS Nesting
We can test this in our SLS machine from XYZ, the MfgPro230, and provide results and maximum output if you would like to add that to your information. I challenge the designers to work on improving the nesting of this mask to maximize output. Correct me if I’m wrong but I’m getting only about a 50% overlap which would increase output by 1.5x. Since this is essentially a bowl I would hope for more overlap.
Tudorprinter
Tue, 2020-04-07 07:25
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Needs soft something to make it air tight
I have printed the mask medium sized . Admittedly in PLA on my Ultimaker 2+. I cut up a surgical mask to create a filter. Even when held tight, it is obvious that there is a leak around/above the nose. After a few minutes I could feel my face getting hot.
If this is intended to provide better protection than a surgical mask, then it needs a gasket to make an airtight fit. If it is not intended to be any better than a surgical mask then it has achieved its purpose but in truth is over engineered.
John Giordano
Tue, 2020-04-07 08:07
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SLS Material
What SLS material was used in the clinical testing model?
clothbot
Tue, 2020-04-07 11:02
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Mould/mold for food-grade silicone?
Hi Everyone,
Two-part question (aka. two+ questions):
Q1a: Could masks made of food-safe/food-grade silicone (i.e. not medical-grade implantable, and not "dirtier" construction-grade) be sterilized using existing accepted methods?
Q1b: Could translucent (i.e no colouring additives) "kitchen and bath" silicone from a reputable manufacturer be substituted, assuming they are variants spec'd as waterproof and rated for temperatures up to 400F?
Q2: Assuming yes to Q1 (a and/or b), could someone with better design-for-manufacturing skills than I whip up a 2+2-part FDM-printable variant of this mask where:
Thoughts?
Andrew.
CEITech
Tue, 2020-04-07 12:30
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File Request for Injection Mold
Hello all,
Great work to all who designed this device!
I am writing to request the original part files (or .STEP, at the least) of the version design shown in the pictures, located under "EXTRA"
This model in particular:
https://3dprint.nih.gov/sites/default/files/models/additional_images/pic3_0.jpg
The placement of the face strap lugs on this model is ideal for our injection molding setup, will require less molding inserts, and will allow us to rapidly manufacture these for our Indiana hospitals.
We will gladly share the injection mold design files to help rapidly get this out. Our cycle times are one mask in less than 1 minute.
Please let me know if I can get the requested model. If so, we start injecting tomorrow.
CarlaLuzzi
Tue, 2020-04-07 16:18
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Validation Test Results
Hi Chris, would you be able to make the validation test results available?
Thank you
phil
Tue, 2020-04-07 16:36
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Injection Molding
I think this is a great design - I'd like to get my team focused on adapting this design for injection molding so we can ramp up production like folks have done with the Montana Mask. Can someone from the design team contact me?
Fran Atkins
Tue, 2020-04-07 16:55
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Duke U Study on PLA Sterilizing
https://techcrunch.com/2020/03/27/duke-university-uses-vaporized-hydrogen-peroxide-to-clean-n95-face-masks-for-reuse/
michael78
Tue, 2020-04-07 16:56
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completely new to 3d printing stuff but desperate.
My homecare agency has 0 masks, the ones we had ordered are evidently delivered and or stolen. I'm desperate to get our staff of 25 folks safe. I've looked at the documentation and I think I could do this, but I would very much like some assistance. I'll happily pay someone to create these for us too. what is the filter material are you recommending using?
I really need help.
Matthew Fiedler
Tue, 2020-04-07 18:20
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request for FDM version
+1 for the FDM version to be reviewed and approved
nicholas.cavaliere
Tue, 2020-04-07 18:41
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Raw Files
In the absence of any parametric files, I have extracted the inner and outer surfaces and converted them to STP/IGES formats. If any official agency requires these files for printing/toolpath generation please feel free to use the contact feature here and I'll email them over.
michael78
Tue, 2020-04-07 20:36
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What's the best approach
complete newbie here that needs masks for his staff. I'm wanting to try this out. What's a 'good enough' 3d printer to use for printing a few of these, I need about 40 for resuse, and more... I'd like to start ASAP. is there a recommended printer and supply of filament to use? I'll look at the guides. could use some help.
513-403-648 Nine is my number
CM3D
Tue, 2020-04-07 21:09
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Dremel
Successfully printed small and medium versions on Dremel with Nylon however was not satisfied with the quality. We have Stratasys F170 machines with PLA or ABSM30, would either of those materials meet requirements?
ScottacusPrime
Thu, 2020-04-09 16:31
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Fangled edges Issue
Hey guys, Has anyone else had issues with the FDM 3D Printing of these masks? Specifically the flanges? It seems like they are too thin and curve to steeply to be properly printed at regular layer heights.
vinhlam72
Thu, 2020-04-09 20:31
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2D files
Hi Chris,
Do you have 2D files (step or Parasolid files) so I can create a mold for injection molding? Thank you.
babblefish
Thu, 2020-04-09 23:03
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Remix for easier FDM printing
I did a remix of the medium size mask to make it easier to print on an FDM printer. I moved the retaining lip from the front to the inside so that the mask can be printed with a flat face on the build plate. I haven't printed one out yet so I don't know if there will be inteference with your nose or not. If it works OK, I can do the small size too.
BCPLemanski
Fri, 2020-04-10 10:23
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NYLON 680 FFD
Hi Chris,
I have no idea where to place this or send it to - our group has done some sterility work on the use of Nylon 680 in steam autoclaves and have found that nylon survives this process with minimal dimensional changes, minimal mechanical changes, and showcases no growth on incubated plates. While this work is by no means done to an ISO level (it was preliminary research into the feasibility of sterilizing FDM parts with sterility validation provided by Steris), I figure I'd pass that along. Our work was to be presented at ARVO 2020 but this was canceled due to COVID. My understanding is that the abstract will be published in IOVS, but I don't know when that will be done. In our study, the nylon must be dried before use and printed at high resolution (160 Microns - we used a Lulzbot TAZ 6) and support use must be minimal. Also the infill must be 100% or the part cannot be made sterile (we have data on this too).
Let me know if you have any additional questions or if you can point me a particular direction.
regards,
Brian - Brian.lemanski@gmail.com
nickjgates
Fri, 2020-04-10 13:24
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Prusa i3 Mk3 Successful Print
I reoriented the design and added supports. I can report a sucessful print on my Prusa i3 MK3. 8.5 hr print.
gcode here: https://3dprint.nih.gov/builds/nickjgates/stopgap-surgical-facemask-pla
pheuss
Sun, 2020-04-12 13:08
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CAD files
the link for the solidworks files seems to be broken. could someone look at the links or direct me to another source of these files. thank you
jazzjensen
Sun, 2020-04-12 13:14
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Solid Works files?
Hello,
I see that there are solid works files ".sldprt" on the downloads page now. However, clicking on the links only yield gibberish- maybe source files? Is there a trick to downloading them? or could the links be updated to download the actual files?
Thanks!
Mohit.Varikuti
Sun, 2020-04-12 16:18
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Any print material available in Amazon can be used for mask?
Hi All,
I printed one model using PLA in my printer (UltiMaker 2) - (only for testing). It was printed nice.
I would like to know few things:
1. Link to website or amazon to buy printer material ( my dad brought me PLA and after reading the messages that is not usable)
2. Link to website to buy Filter's
3. Link to webiste to buy elastic.
Thanks
Mohit
tasmuth
Sun, 2020-04-12 22:30
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Submitted remix with thicker shell
I have submitted a remix with a slightly thicker shell and parts of the cover thickened for strength. I am experimenting with Vat Polymerization printing (Form Labs Form 2).
matthewstuartwade
Mon, 2020-04-13 11:30
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download problems
Hello, I hope I am not wasting anyone's time. When I click to download the stl no problem. When I click to download the sldprt file it opens another tab in chrome and is the basic code for the model. Is there a problem whith the link or chrome? Please, advise. Awesome work btw.
EWOLF
Mon, 2020-04-13 14:46
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CAD FILES NOT DOWNLOADING?
Hi, when I click on the link for SW files, I get linked to a webpage rather than a download. STL files download correctly. Any ideas on how to fix this?
EWOLF
Mon, 2020-04-13 15:20
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SW FILES
Hi, I am looking for a link to download the SW files. STLs download fine, but I cannot download the CAD files. Any help would be appreciated.
TejMehta
Tue, 2020-04-14 15:09
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FDM Remix
Hello,
This is an excellent design and I applaud the original authors for their work! I have remixed this design for easier printing on FDM machines using TPU for the mask body and PLA for the cartridges. I've also included optional straps for the mask, which I've printed out of TPU. I've successfully printed all components of the mask on a Prusa i3 MK3S, Ender 3 Pro and CR-X. While the original design is excellent, I don't think it easily transfers to the 3D printing modalities most people have available. Please see the link below if this is something you would like to try for yourself.
https://3dprint.nih.gov/discover/3dpx-013841
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