Ultra-fast design and production of custom-fitted reusable FFP2/N95 face masks: combining 3D face scanning and 3D printing technologies (UFM3D)

ActiveCell Technologies is a Leeds-based start-up developing a disruptive offering for rapid prototyping and manufacturing using fusion-deposition technology -- a 3D-printing farm where any item can be sent to print instantly and monitored remotely.

In project UFM3D, ActiveCell will develop an innovative process for the rapid design and manufacture of reusable N95/FFP2 filtering masks to address 1) the current shortage in respirators for frontline workers, responsively and at scale 2) the issue of face fitting of said respirators.

ActiveCell Technologies will develop a mobile app able to generate a 3D scan of the face of the user, and the back-end software to process this data automatically to convert it into a model for the 3D-printing of a respirator. It will also develop and test a respirator, based on a peer-reviewed published design. 100 units will be produced within 6 months and tested with frontline workers at the NHS, before the full implementation of the service.

In the longer term, a service for on-demand manufacturing of perfectly fitted filtering face masks will be available to both the NHS and the general public.

Extension: Given recent government directives making face covering and masks mandatory for all in public spaces, demand for our reusable N95/FFP2 face-fitting filtering masks is expected to be higher than originally anticipated. To be able to answer this demand, we need to improve and optimise our manufacturing operations by automating the process from the point of reception of an order, up to packaging and address-labelling the finished product. We intend to design and develop the prototype of a fully automated machine that would enable us to combine two to three of our current devices, making it possible to reach a production rate of 350 to 400 masks per day, twice what we are currently able to produce.