55111Mass production of re-usable surgical and N95 style face masks made from Polyurethane foamClosedFeasibility StudiesInnovate UKUrofoam Ltd has been manufacturing technical polyurethane products in the UK for the past 30 years. We are specialists in mass-produced moulded foam components, servicing industries such as; sports, automotive, aerospace, oil and medical. As a result of the impact of Covid-19, we have focused our attention on developing a washable and reusable face mask to help meet the nation's shortfall in supply. The mask will have performance characteristics comparable to those in the market at the moment, can begin production within a month and can be mass-produced. The face mask is made from a moulded polyurethane foam which allows air to flow both ways and is designed to filter airborne droplets from both the wearer and the surrounding area. Because it is washable and reusable it is designed to be used in sub-clinical healthcare areas such as hospital cleaners, porters, ancillary staff, care workers. It is not designed for intimate healthcare contact where single-use, disposable masks destined for incineration would be most appropriate. Current masks are produced using either polyester or wood pulp fibres, each having limitations from a supply chain perspective. Our polyurethane mask sources almost all materials from the UK, with the remainder coming from Germany. As part of the moulding process, we can also incorporate antiviral and antimicrobial compounds which limit the risk of transmission. Our intention is to convert 3 of our 4 volume production lines to produce masks, with an initial output in excess of 20,000 units per week.