Automated Generation of Custom Fit PPE Inserts

This research presents a machine learning-based interactive design method for the creation of customized inserts that improve the fit of the PPE 3M 1863 and 3M 8833 respiratory face masks. These two models are the most commonly used by doctors and professionals during the recent covid19 pandemic. The proper fit of the mask is crucial for their performance. Characteristics and fit of current leading market brands were analyzed to develop a parametric design software workflow that results in a 3D printed insert customized to specific facial features and the mask that will be used. The insert provides a perfect fit for the respirator mask. Statistical face meshes were generated from an anthropometric database, and 3D facial scans and photos were taken from 200 doctors and nurses on an NHS trust hospital. The software workflow can start from either a 2D image of the face (picture) or a 3D mesh taken from a scanning device. The platform uses machine learning and a parametric design workflow based on key performance facial parameters to output the insert between the face and the 3M masks. It also generates the 3d printing file, which can be processed onsite at the hospital. The 2D image approach and the 3D scan approach initializing the system were digitally compared, and the resultant inserts were physically tested by 20 frontline personnel in an NHS trust hospital. Finally, we demonstrate the criticality of proper fit on masks for doctors and nurses and the versatility of our approach augmenting an already tested product through customized digital design and fabrication.