Vacuum Formed Mask

The vacuum formed BEclear mask system is a lightweight reusable clear mask adapter combined with a certified face mask.

Design and Features

Mask BEclear v1.0
Production ProcessVacuum Forming / 3D Printing
TransparentYes
Body MaterialFoodsafe PETG plastic (polyethylene terephthalate)
Weight20 grams
Cost$$
FilterKF94 Spun Polypropylene (Manufactured by AllkeeperMask.com)
StrappingEars, or around head using an ear-saver (not supplied)
Recyclable MaterialsYes (clear shell)
SizingAdjustable and Customizable
Testing AvailableNo

Pros

  • Home production version can be produced with consumer vaccuum forming machine and inexpensive clear PET plastic sheets
  • Made from clear lightweight materials for optimized social communication
    • Design utilizes existing strapping of consumer mask
  • Easy to replace consumer mask filter for single or limited use
  • Reusable and washable, easy to spot clean and treat for Anti-Fogging
  • Size variability supported to adjust mask fit on variety of faces
    • If the mask is too large, plastic edge can be trimmed at the top using scissors
  • Clear mask body can be removed and soft mask ‘filter’ can be worn for alternative option
  • Open source design includes variations of STL files and production guide

Cons

  • Large start up cost for consumer vaccuum forming machine
  • On DIY model, cutting out individual masks is time intensive in larger batches
  • Dependent on availablity of consumer masks as filter
  • Currently one size fits all 
  • Mask body material may warp in dishwasher or autoclave (wash by hand)

User Guide

Current User Guide


Assembly

1. Place adapter face down on a clean surface. Remove brown adhesive backing. Apply sticky tape to the bottom edge of the adapter, pressing into the groove and extending out to the sides.

1. Place adapter face down on a clean surface. Remove brown adhesive backing. Apply sticky tape to the bottom edge of the adapter, pressing into the groove and extending out to the sides.


2. Fold free ends in half (sticky to sticky) and remove white backing. This creates two "double-adhesive tabs"

2. Fold free ends in half (sticky to sticky) and remove white backing. This creates two “double-adhesive tabs”


3. Open mask, face side up, and position over the adapter as shown, aligning the adhesive with the outer surface of the side that does not have a rectangular insert.

3. Open mask, face side up, and position over the adapter as shown, aligning the adhesive with the outer surface of the side that does not have a rectangular insert.


4. Bend the free doubled-adhesive-tabs around to adhere to the inside of the mask.

4. Bend the free doubled-adhesive-tabs around to adhere to the inside of the mask.


5. Pull the mask to the bottom of the adapter and squeeze to adhere the interior of the mask to the doubled adhesive tabs. Do not pull the mask around the chin straps. Place the adapter it on your face and slide the bolo buckle upward on the chin straps, to find a size that fits your face when your lips are slightly parted. Lock the bolo buckle in place by bending the plastic straps away from each other.

5. Pull the mask to the bottom of the adapter and squeeze to adhere the interior of the mask to the doubled adhesive tabs. Do not pull the mask around the chin straps. Place the adapter it on your face and slide the bolo buckle upward on the chin straps, to find a size that fits your face when your lips are slightly parted. Lock the bolo buckle in place by bending the plastic straps away from each other.


6. Pull the chin of the mask around the mask, bolo buckle and chin straps. Place the mask and adapter on your face, and put the strips around your ears. If there is a gap between the mask and the underside of you neck, you can fold the rectangular metal insert over.

6. Pull the chin of the mask around the mask, bolo buckle and chin straps. Place the mask and adapter on your face, and put the strips around your ears. If there is a gap between the mask and the underside of you neck, you can fold the rectangular metal insert over.


Use included clear comfort strips for fine tuning comfort and fit under your chin. Remove the strip from it's plastic backing. Fold in half, sticky side out and insert the fold into the "V" where the two chin straps converge. Unfurl the clear comfort strip to make a soft "cradle" for your chin.

Optional:
Use included clear comfort strips for fine tuning comfort and fit under your chin. Remove the strip from it’s plastic backing. Fold in half, sticky side out and insert the fold into the “V” where the two chin straps converge. Unfurl the clear comfort strip to make a soft “cradle” for your chin.


Use included clear comfort strips to create an airtight cradle for the bridge of your nose. Remove the strip from it's plastic backing. Fold in half, sticky side out and insert the fold into the "V" at the bridge of the nose. Unfurl the clear comfort strip to make a soft airtight "cradle" for your nose.


Optional:
Use included clear comfort strips to create an airtight cradle for the bridge of your nose. Remove the strip from it’s plastic backing. Fold in half, sticky side out and insert the fold into the “V” at the bridge of the nose. Unfurl the clear comfort strip to make a soft airtight “cradle” for your nose.


Narrow the protective margin surrounding the mask by trimming away excess plastic.


Optional:
Narrow the protective margin surrounding the mask by trimming away excess plastic.



Use & Fit

Prevention of general mask fogging

  • Masks will fog in humid or cold environments, when transitioning between environments, or when worn for an extended period of time while speaking or breathing heavily.
  • Fogging can be greatly reduced by placing a drop or two of liquid dish/hand soap on the mask and rubbing it on the surface round. Reapply as needed.
  • You can also switch between two masks every hour or two, to allow one to air out and de-fog.

Leaking of air or fogging of glasses around the nose

  • If leaking occurs around the bridge of the nose, use the optional silicone gasket to optimize the fit.
  • Fit documentation
  • Optional features explored
    • Snap filter attachment (for quick and easy changing)
    • Simple nose gasket for cushioning with skin safe materials
    • Convertible transparent straps (ear loops or head strap)

Care & Sanitization

The adapter shell can be washed in warm soapy water.  It should be clean when it is put on, and should be cleaned periodically, especially after any possible exposure to pathogens. 

  • To clean and sanitize, peel the facemask away from the clear shell.
  • Remove any remaining adhesive strips
  • Wash the clear shell in soapy water.
  • Dry shell and replace the adhesive strips.
  • Replace facemask.
  • For full sanitization recommendations, follow Care + Sanitation documentation

Production and Distribution

The clear shell is produced by vacuforming a PETG sheet over a 3D-printed mold, and then trimming the PETG sheet.

  • STL files for the mold are available HERE.
  • Any consumer grade 3D printer will be adequate to the task.
  • An easy to use, relatively inexpensive vacuforming system Maykuform device, available for around $700.
  • Trimming: cut the vacuformed shell along as illustrated here.
  • Combine the Trimmed shell with the AllKeeper mask using the adhesive, as documented in Assembly (above).

Testing

Team Testing April/2021

Data obtained using Particle Counter, comparing particle count inside box to outflow on downstream side of filter. 3D printed Head used to hold masks. Head inserted onto 2” PVC pipe. Pipe provides outflow using vacuum pump


Certified KF94 Mask Testing

Facemasks provide protection by filtering or blocking particles and droplets.  

  • Information about the KF94 certification (a Korean standard similar to the US KN95 standard)  is available here.  
  • The clear shell provides a potentially air-tight non-porous barrier. Personal fit will determine whether there is any leakage around the edges of the shell. As with any facemask, individual fit testing and adjustments are recommended.
  • Breatheablity of the KF94 mask may be slightly improved by the chin loop in our mask system because more internal filtration surface is exposed. 

Vaccuum Form FAQ


Q. Can this mask be produced at home?

A. Yes, the mask can be produced using a consumer 3D printer and a vacuum forming machine.  .

Q. Are the materials skin-safe?

A. For the DIY design, we have used .5mm PETG plastic (polyethylene terephthalate) which is a polyester and skin-safe plastic. This is the same material used soda bottles and frequently found in take-out food containers. The material is very clear, although the production process occationally includes faint marking and artifacting.

Q. Are there recommended 3D printers and settings?

A. Yes, please refer to the 3D Printing FAQ


The BE mask is offered to the general public for general, non-medical purposes. In accord with FDA Emergency Use Authorization, it has been submitted for review to NIOSH. The safety and efficacy of any mask depends on fitting, sanitization practices, and filter materials. Any mask should be tested and fit to meet local needs and standards. Please see our user liability disclaimer for details.