A Mask for the masses

I like you am worried about the Covid-19 Virus. I feel we should all be using universal precautions. But that's my background talking. I have certifications in air/blood borne pathogens, Clean/sterile field protocol training, EPA 608 Universal, 15yrs of fabrication and material sciences... I like most of you on here am also a nerdy problem solver.
I take a big issue with a shortage of masks for adults and little to no working masks for kids. ( I have to little girls). So I started researching, after 90hrs of patent and material research. I worked out a solution that uses Viral rated materials in a manner; in alignment with the N95 Patent. The printed mask minimizes the amount of filter material needed.

Build list:
3M filtrete 1900 air filter ( this air filter is for home AC units and is viral rated)
vent filters( this is structural filter material used to help with air flow and middle layer effectiveness)
Foam or felt ( I like both, but that's me. used for padding and comfort)
elastic straps( head straps, The file has 1 inch holes. Size to what you have)
spray adhesive( for these kind of things you need something that gets everywhere and works well with foam and felt)

The Mask:
I printed no supports with the chin on the build plate, 100% perfect. FDM's and larger SLA's could print with the face contact side on the plate for faster times. I built both faces for printing
SLA prints. do not use 90% to clean. use that for better things, plus this is a mask. clean it right and use ethanol. you'll have a better product at the end.
once printed. heat up the nose piece with a blow drier on high, to soften it for molding.
press the mask up to your face ( make sure it isn't to hot, but that the material is soft)
press on to and pinch your nose and allow to cool to lock in the shape of your nose.
cover the Nose piece on the inside with foam. Comfort is key.
loop the elastic through the holes and make sure you measure and cut the elastic a little short. needs tension to work.
secure your elastic ( I used high temp acrylic hot glue and created little loops and secured)
cover all face contact points with felt. ( once again comfort is key)
your mask should now be assembled. Let's talk filter

The filter uses viral rated materials, made by the leading manufacturer of N95 masks. So wouldn't you know it when I looked at patents and found that the 1900 series air filter is the same filter material as the N95. the 1900 uses one layer and the N95 uses 3 layers with 2 structural filter material layers.
So let's Make a Filter ( I have had "Making a Filter" from Bio-dome stuck in my head for days now)
first disassemble the 1900 series filter. careful for the meshing, it is sharp, I have a nice cut to prove it. but remove it with as little damage as possible to the surface area. remove the frame and you will have 40 inches by 25 inch of material to work with ( give or take a little)
using the med_maskLg_B print trace the inside space on to some paper ( I like Card stock). cut it out, you now have your filter template.
to make one filter you will need 3 layers of 1900 series and 2 layers cut from the vent filter. all using your template.
the layers should be 1900/vent/1900/vent/1900
compress these layers down to around 13mm.
seal the ends with hot glue ( Not high heat acrylic, it will melt and destroy the filter)
slide it into med_maskLg_B and insert into your mask.
if you've done it right, the only air flow you should feel when worn is through the filter.
use a blow drier to make minor shape changes.
But please hack it up change it, just make sure it will still be safe. Mine is Soundwaves G1 grill.
Any claims of safety about the filter design is based on research, personal knowledge and experience, The FDA has Not approved this filter Hack or design. it is in alignment with 3M's patent but not a direct infringement on the patent. Please be safe

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