Development of a Customized Mask Frame Using a 3D Facial Scan for an Airtight Seal for Disposable Surgical Face Masks

The present study focuses on the design and development of a custom frame, using an individual's 3D custom facial scan, to improve the seal of the existing surgical masks. Three participants' facial scans with a wide range of facial dimensions were collected using a 3D hand-held scanner. During design, the contact area between the custom mask frame and the wearer's skin was determined based on an individual's 3D facial shape. To evaluate the effectiveness of the airtight seal, a qualitative fit (smell/taste) test kit and thermal image camera were utilized. When the participants wore the surgical masks without the customized mask frames to securely fit the surgical masks, the participants smelled the saccharine scent from the test kit. However, while wearing the surgical masks fitted with the custom mask frame that held the mask in place, none of the participants could smell the scent. In addition, thermal images showed ambient temperature changes in a surgical mask suggesting air leakage around the boundary of the mask, while the subject was inhaling and exhaling. The thermal images confirmed the effectiveness of the custom frame to block the inflow/outflow of air potentially carrying the virus. The developed custom mask frame will be particularly beneficial for frontline medical staff members who treat patients with infectious viruses transmitted through aerosols as part of their PPE.