Hrvatski
Español
English version
Croatian 3D printed respirator

Our team in Croatia has designed a makeshift respirator for medical staff. We call it CroResp: Respirator with eye protection made from a diving mask, adapter and virus filter. The respirator is designed for personal use at the discretion of medical professionals in the case of lack of certified and tested protective equipment.

The respirator is intended to protect the airways and eyes of medical personnel, especially those who carry out procedures where aerosol is generated by coronavirus infected patients. The respirator can be made of parts currently available in Croatia and most likely many other countries. 

FULL FACE DIVING MASK + ADAPTER MADE BY 3D PRINTING PROCESS + VIRUS FILTER = RESPIRATOR.

Updates

We don’t have the resources to keep the English version of our page continuously updated. We will post regular updates as voice memos to speed the dissemination of knowledge. Latest 3D models will also always be up to date.

03/05/2020

04/04/2020

New and improved versions of adapters for both the Decathlon and ExtremeSub masks. 

03/04/2020

Further below you can find the project details, including instructions for making and assembly, adapter models for 3D printing, and the instructions for the safest possible use. 

Content:

PROPOSAL

We suggest an innovative device for respiratory and eye protection.

The device is based on the existing diving masks that cover the entire face, allowing for panoramic viewing and the ability to breathe through the nose. The device is made from a Decathlon full-face snorkeling mask (HR reference numbers: 8315702, 852611, 8315702), and masks from other manufacturers of similar equipment, such as Extreme Sub.

During the design process, the snorkel is removed and a special adapter created by the 3D printing process is connected in its place. Finally, a medical filter for viruses  (a disposable, accessible and relatively inexpensive device widely used in medicine) is attached to the adapter.

MOTIVATION

Due to the pandemic of coronavirus we are witnessing a major global shortage of personal protective equipment (PPE). The seriousness of the lack of PPE is also evident from the fact that in many countries of the world there is not enough equipment even for medical staff, who are at highest risk of infection. Due to this new and rapidly evolving situation, medical staff are forced to use equipment with a low level of protection against the new coronavirus.

In the absence of standardized and tested respirators and masks, medical staff currently use respirators with a lower percentage of small particle filtration or a pair of ordinary masks, such as surgical masks. There is also a lack of eye protection equipment which could be used to prevent the virus from penetrating the body via the eye mucosa, such as sealed protective goggles. In such a situation, medical personnel are directly exposed to viral particles, especially during procedures such as intubation, in which large amounts of aerosol are generated.

This situation is not good for at least three reasons: First, medical staff are forced to risk their own health; second, sick medical staff members cannot work and treat other patients; third, infected medical staff members become the spreaders of the infection.

IDEAS AND INSPIRATION

This project was inspired by the pioneering efforts of two groups from Italy and the United States.

The Italian company Isinnova, in collaboration with Dr. Renato Favero of Gardona Val Trompia Hospital in Italy, made a 3D printed replacement ventilator valve used to treat patients, and then a non-invasive ventilation mask based on the Decathlon diving mask. Non-invasive ventilation is currently widely used in Italian hospitals to support the breathing of patients who are in a serious (but not critical) condition and do not require immediate intubation and invasive ventilation.

At the same time, a group from the United States (Boston Children’s Hospital) has proposed an innovative way of making a device that, in the absence of PPE, can replace a respirator for the personal protection of medical personnel. They suggested and presented a way to make a respirator out of an anesthetic mask, a viral filter and elastic bands, parts that should still be widely available.

This project is a combination of the above methods. To create the proposed respirator with eye protection, we use the Italian idea of a diving mask and we have customized their adapter for our proposed respirator. From the US group, we take the idea of using a virus filter that we connect to an adapter created by 3D printing.

Adapter making and Respirator assembly

Decathlon diving mask

Dacathlon respirator - 3D print

Materials needed:

  1. Full face diving mask from Decathlon
  2. Virus Filter Adapter – made by 3D printing process
  3. Medical filter for viruses, with the highest filtration rate available
  4. Flat screwdriver
Adapter 3D printing:

Because different manufactures and models of masks exist, with different connectors to which the adapter is connected, we created two different models. One for the Decathlon mask, based on which the original Italian project was made, and the other a new connector for the ExtremeSub mask. A similar adapter can be made for any other similar full face diving mask, but it is also advisable to choose one that is widely available and affordable in your location.

This is the first final version of the print file, completed after a dozen of improvements and testing of the printed adapters. Further modifications may be made after testing for practical application by the medical personnel and further testing. 

 

All suggestions are welcome, and the attached files are free to use and modify, on condition that the adapters are donated, or that they are charged only in the amount that covers the costs of production. They must not be used for commercial production and for-profit sales. 

File – Adapter for Decathlon mask: 
Adapter_Decathlon_V2.1_pandemija.info.stl 

 

Updates from v1:

  • much better connection and thicker walls
  • wider opening for the viral filter (easier breathing)
  • no clip (not needed, no support needed, faster printing)

Recommended print settings:
Layer: 0.2 mm
Infill: 20%
Filament: PLA or PETG
Position: vertical, wider part at the bottom
Brim: on

Assembly procedure:

  1. Remove the vent valve protection at the front side of the mask. This valve otherwise serves to drain small quantity of water that can accumulate inside the mask during a diving
  2. Remove the membrane, flip it, and place it back in the same place in the mask – STILL TESTING/DEBATING THE POSITION OF VALVE
  3. Return the vent valve protection to its initial position
  4. Remove the valves that separate two chambers from the inside of the mask, located adjacent to the nose section
  5. Attach the 3D printed adapter for the virus filters to the snorkel connector at the top of the mask.
  6. Attach the virus filter to the 3D printed adapter.

Extreme Sub diving mask

Materials needed:

  1. Full face diving mask from Extreme Sub 
  2. Virus Filter Adapter – created by 3D printing process
  3. Medical filter for viruses, with the highest filtration rate available
  4. Flat screwdriver

Adapter 3D printing:

This is the first final version of the print file, made after a dozen of improvements and testings of the printed adapters. Further modifications may be made after testing for practical application by the medical personnel and further testing. 

 

All suggestions are welcome, and the attached files are free to use and modify, on condition that the adapters are donated, or that they are charged only in the amount that covers the costs of production. They must not be used for commercial production and for-profit sales. 

File – Adapter for ExtremeSub mask: Adapter_ExtremeSub_V2.1_pandemija.info.stl

Updates from v1.1:

  • slightly enlarged opening towards the mask and channels of the clip (easier disassembly)
  • wider opening for the viral filter (easier breathing)
  • added CroResp logo

Recommended print settings:
Layer: 0.2 mm
Infill: 20%
Filament: PLA or PETG
Position: vertical, wider part at the bottom
Brim: on

Assembly procedure:

1. Remove the vent valve protection at the front side of the mask. This valve otherwise serves to drain small quantity of water that can accumulate inside the mask during a diving
2. Remove the membrane, flip it, and place it back in the same place in the mask – STILL TESTING/DEBATING THE POSITION OF VALVE
3. Return the vent valve protection to its initial position
4. Remove the valves that separates two chambers from the inside of the mask, located adjacent to the nose section
5. Attach the 3D printed adapter for the virus filters to the snorkel connector at the top of the mask.
6. Attach the virus filter to the 3D printed adapter.

License to make the virus filter adapter

Our modification of the virus filter adapter is based on the one made by the company Isinnova from Italy. They have initiated patent protection, but solely for the purpose to ensure its free use.

Issinova states that it has published drawings, models, logic and all other intellectual property rights pertaining to the Charlotte valve device, and permits free use and production provided it is NOT used for commercial purposes. Our modification of the adapter is subject to the same rules. Since this is a modification of the Charlotte valve, we believe that the proposed adapter is subject to the same rules. So feel free to create and use it for non-commercial purposes.

Use of the proposed respirator

USE AT OWN RISK!

The proposed equipment has not been tested and it does not have the certificates for use issued by competent bodies. This equipment must not be used if you already have an approved PPE. Use this equipment only when you do not have an adequate PPE. You use the equipment on your own responsibility.

The authors of the equipment and people creating pandemija.info web page are not responsible for any guarantees, written or implied, including the quality, suitability and additional uses, and they will not be responsible for any losses or damages that arise from using this equipment.  

YOU USE THIS ON YOUR OWN RESPONSIBILITY! 

Instructions for using the respirator with eye protection

At this moment we are not familiar with all the possible risks of using the proposed respirator. We have not conducted the sealing tests (to check if and how much air flows around the mask and its joints, apart from the air coming through the filter) and we do not have precise data on the filtration capacity of the virus filter. 

IMPORTANT! There are many models of virus filters on the market, by different manufacturers.  

Read the instructions and specification of the manufacturer. Always use a filter with the highest percentage of filtration possible. In the manufacturer’s instructions you will find the information on the level of filtration, expressed in percentages. For example, the stated level of filtration of Intersurgical Filta-Guard is 99.999%.

The example of virus filters. Virus filters can have different filtration efficiency, different shapes, additional apertures, but the connecting tubes have standard diameters, regardless of the manufacturer.   

How to check the size and seal of the mask

It would be ideal if you try on the mask and see how it seals on your face, with an assistant who would monitor the procedure.

The mask may not fit everyone, but you can find different sizes. Decathlon and Extreme Sub masks are available in two sizes for adults.  

Decathlon 
– Size S / M, for adults with thinner faces, women and children older than 10. 
– Size M / L, which fits the average size of an adult person’s face.

Extreme Sub
– Size S / M
– Size L/ XL

  1. Make sure that your facial hair, hair, jewelry, glasses, clothes or any other item does not obstruct a proper sealing of the mask on your face. Men have to shave off their beards! 
  2. When you put the mask on, check if there is any space between the bottom of the mask and your chin. If there is any free space, the mask is too big for your face.Provjera veličine i brtvljenja maske
  3. Put the mask on your face. Pull the strap over your head. Fasten the strap using the two fasteners, to make sure the mask seals properly on your face. The strap has to be centered on top of your head.  
  4. You can conduct your own sealing test by reaching with your hand and covering the opening of the snorkel, adapter or virus filter. Cover it gently, without applying too much force that might move the mask. Try to breathe in. If you cannot breathe in properly and the mask fits tightly to your face, it means the sealing is good. The next step is to cover the opening again and try to breathe out. If you do not feel the air flowing out around the edges of the mask, it means the sealing is good. If you feel the air flowing around the edges of the mask, try to fit it more properly and fasten the strap more tightly. Then try again. If you still feel the air flowing around the edges of the mask, do not use the mask.  

Putting on the mask

  1. Wash your hands thoroughly with soap and water or alcohol-based hand sanitizer before and after you put on, remove, touch or adjust the mask.
  2. Make sure the mask is not damaged. If there is any damage that may affect the sealing, discard the mask. 
  3. On your own, or ideally with the help of another person, take the front part of the mask and put it on your face. 
  4. Pull the strap over your head. Then use two fasteners to fasten the strap, to ensure a proper sealing. The strap should be centered on top of your head.  
  5. Do a seal check according to the instructions – see above. 

Removing the mask

  1. Do not touch the front of the mask! It could be contaminated!
  2. Remove the mask by pulling the strap over the head without touching the mask.
  3. Properly clean and store or discard the respirator.
  4. Wash your hands.

Instructions for maintenance of respirators with eye protection

  1. Make sure the mask is not damaged.
  2. Make sure that the equipment is not contaminated – with aerosol, blood or other bodily secretions, or condensation inside the mask.
  3. Separate the filter adapter and the virus filter. 
  4. Clean each of the three parts separately – the mask, adapter and filter.
  5. You can wash the mask in water with soapy water or clean it with disinfectant wipes.
  6. You can wash the filter adapter with soapy water or clean it with disinfectant wipes.
  7. Clean the filter for viruses with the wipes, but make sure you don’t get the filter wet. 
  8. Leave all parts to dry.
  9. Put away the respirator in a safe and clean place – we recommend a clean paper bag with clear markings.

When to change the virus filter?

  1. If breathing through a filter becomes difficult.
  2. If the filter is dirty or damaged.
  3. After it has been used for a while, depending on availability. We cannot state any specific time of use at this moment and we are trying to obtain more precise information.

The Authors of the Project

The respirator with eye protection made from a diving mask, adapters and medical filters for viruses was created by a group of people running the website https://pandemija.info, which is an online database of useful guidelines and educational materials from around the world intended for medical personnel to help them fight the new coronavirus.

The project would not be possible without the work of the company Isinnova from Italy, in collaboration with dr. Renato Favero from the Gardona Val Trompia Hospital and a group at Children’s Hospital in Boston, USA. We are very thankul for their dedicated work and for sharing their innovations for free.

Ivor Kovic, MD
Proposed the modification of Italian model and the modification of the innovated equipment into protective respirator. He also prepared the documentation for design and use.

Ivan Gustin and Marko Gustin
Designed and tested new adapters through the 3D printing process and conducted the initial respiratory tests.

Hrvoje Vukelic
Organized the procurement of test diving masks and virus filters and coordinated the team work. 

Acknowledgments:

Branimir Lozo – donated a test diving mask from Decathlon.

Igor Habljak – handles the supply of diving masks for our team; arranged for the first donation of Extreme Sub test diving masks from Darko Majcan from the company Kupanac, Zagreb.

Kruno Golubić – providing assistance with the website and social media presence.

Matija Ilijaš – coordinating makers that produce CroResp masks in Croatia.

Ivan Zovak – owner of Zovak company from Zagreb, donated a large number of scuba masks for testing.

Petra Počanić – global community coordinator

Krešimira Rendulić – head of public relations

Translation: Natalija Pejnović, Thais Erna Mandalinić, Branimir Matoz, Mihaela Jurković

Proofreading and editing: Lidija Toman, STIP Rijeka

Logo design:
Igor Manasteriotti – the art director of Manasteriotti DS, an award-winning design studio from Croatia which specializes in branding of people, products and companies.

Medical collaborators:
Mario Franolić, MD
Emergency medicine specialist and mentor at the Department of Underwater and Hyperbaric Medicine at Clinical Hospital Center of Rijeka.

Vedran Radonić, MD
Cardiology resident at Merkur Clinical Hospital in Zagreb. Before that he has worked at the ambulance service of Sisačko Moslavačka county.

kontakt
Scroll to Top