Design issue, face mask cap keeps falling off like 90% of the time

[ekawahyu]

FYI, I have printed this face mask. The biggest issue with this mask is its front cap keeps falling off. We are gonna let a bunch of different 3D printers to do this, so having moving part really is a bad idea. We could get rid of the cap and put a fixed grill vent like 2-3 mm thick in front. The filter can be replaced from the inside.

I have no success so far with my machine to convert this STL into editable solid in FreeCAD. If someone can help with converting it, that would be helpful.

[sam598]

I am not an expert, this is all pure speculation.

I am wondering if the purpose of the removable cap is to make cleaning the mask easier?

Would it be possible to use some kind of tape or something similar to hold the face cap in place? Even if it was a perfect fit and did not fall off, I would imagine it would be good practice to tape the cap anyway since crevices could let unfiltered air in.

[netkruzer]

I haven't had any trouble with the cap not staying in place. It seems to be very snug.

As for importing the files, I was able to import the STLs into Solidworks, but I did not try editing them. Usually STLs are very difficult to edit. I can see if Darryl wants to share his STEP or Solidworks files.

[ekawahyu]

@netkruzer it is staying in place when it comes out fresh from the printer. After just few days of wearing it, like if you push it a little hard against your cheek or your nose, then it starts falling off.

Do you think you can suggest Darryl to modify it, add a grill vent (2-3mm thick) right on the face mask? So, no cap necessary, the filter can be replaced from inside only.

[netkruzer]

Oh! you are actually wearing this! Great feedback to have, I haven't worn one at all.

I will mention this to him. From a youtube video, it looked like the HEPA filter was just installed around the inside grill, so the front cap could be included in the main mask. I have a HEPA filter coming today or tomorrow so I'll try it out too.

[jgwinner]

I can model that. Working on it now.

[jgwinner]

I have a test model all done, I call it "The Pencil Popper". I also just merged teh old mask, but then you need a letter opener to pop the cap off.

I think though, it depends where you put the filter material. Maybe the cap needs to have holes so it can be tied to the mask. If you put the filter material between the outside of the mask and the cap, obviously an integrated cap won't work.

[WhatUpBigUp]

is there a need to have 3 parts to the mask or can the front grill be integrated into the mask? The square grill would be the only additional piece to print and assemble, reducing time and material to print.

[netkruzer]

@WhatUpBigUp We are working on getting the design down to 2 parts, the grid and the main mask, the only part that was an issue is being able to push the grid out from the front. One member is printing a version with a pencil/pen hole to push it out from the front.