Powered, Air-Purifying Respirator (PAPR) Mod for CPAP face masks and more

*** I’m no longer posting to Thingiverse, or Updates. If you wish to see all my work and updates to items posted to Thingiverse please visit my personal website https://gallaghersart.com/design ,OR Google “GallaghersArt 3D” (GallaghersArt is a single word no spaces). Thingiverse was fun!

Powered, Air-Purifying Respirator (PAPR) Mod for CPAP face masks and more

**Update April 13th finally got some filament and tested some more parts… sorry all I could get was black and they do not take pictures good. 1st Updated both 3M type mounts so 3M cartridges will be vertical once attached. 2nd added Dual 3M mounts for both filters and cartridges. 3rd added test template for Voltmeter face. 4th updated 3M test mount and added the filter test version. 5th Minor changes to battery Bottom with belt. 6th added 8x18650 battery holder with Voltmeter. 7th Updated statistics for powered air from actual usage. more to come...

Apr. 9th 2020 update: 1st Modified battery part for better cable management, 2nd added another Battery cover to house volt regulator, 3rd Update 3M Filter mount and split them into 2 different versions – one for cartridge and one for paper / fabric 3M filter that extends into filter to expand filter so it does not collapse. 4th Resized main parts. 5th added statistics about usage.

This is ongoing, have more things to add to this once I have them printed and ready to go. Please visit my website for more related material and just more. http://gallaghersart.com/page/airtight_adapters_for_medical_masks_and_face_respirators

Using extra parts I had for my 3D printer and an old CPAP hose and face mask I created this powered adapter to filter the incoming air. This would only be good if not sick, no way to filter outgoing air. I made these to be modular. So, I can have different outgoing hose adapters and incoming Filter adapters. Along with a replaceable homemade filter adapter.

I used some XX 24v fans. They can down to 10v, but 12v seems the best for air flow. 24v was too much. Ideally attached to rear of person on there belt. And have any filter also covered with something to extend the filters life.

I have 1 battery module that holds 4x 18560 in series. The battery holders that will give me between 17v and 12v. No electronics just batteries wired directly to fan, so user will have varied flow while using depending on Battery charge. You can also use your own battery Pack. I have one that holds 8x 18650 batteries and I can set the outgoing voltage, so the fan stays consistent.

Once all parts are printed verify everything’s fits together, some sanding with small files works good for me. I made the modules to accept 4x M4 25mm bolts. The Hose attachment just slides on tightly. Parts could also be glued for a permanent setup, resulting in some minor weight saving from not using bolts.

Depending on the way you go this may need to pe printed differently or additional parts.
1# Have own battery pack that will supply 12-18v
2# AC power adapter for those who will be stationary
3# Single unit batteries and fan unit as one, swap out batteries with charged ones
4# Single unit adjustable voltage and charge battery while in use. (Coming soon, I have parts for single unit)

If using Glue

Verify all parts fit including hose and filters before gluing. The correct Air Intake Filer adapter need to be glued to the fan modules air out take. Before gluing verify parts file correctly and line up. Some sanding on a flat surface may need to be done. If fan is loose ads some padding in areas not related to air flow- this will also work for a better air tightness. Warped parts will not work. Clean Parts after a final super fine sanding of surfaces. Apply glue and hold in place until glue hardens. I would not recommend gluing the hose adapter in case hoses changes.

Using Custom 3M ®© Filter adapter

I had some cork vibration gaskets for NEMA 17 motors meant for a future 3D printer. They are 2.9mm thick and when compressed around 1.5mm thick. Much thicker than the rubber gasket on the 3M face masks. Using 3D Printed Gasket template mark and cut out gasket (if using 3M gaskets make sure you print out correct STL for the smaller gap for gasket).

Screw parts together or glue, add the cork/gasket NO GLUE. Give it power without filter on it to verify all good. Then install filter and give it power again. I have noticed that with 3M 209x Filter’s I need around 12v of power. For the big 609xx filters I need @14v to get same result.

Usage Statistics with just 4x 18650 battery wired directly to fan. Using 3M 2091 fabric filter
4.19v batteries to start
16.71v 12:10
16.54v 13:10
16.46v 14:10
16.36v 15:10
16.34v 16:10
16.31v 17:10
16.24v 18:10
16.20v 19:10
16.17v 20:10
16.13v 21:10
16.03v 22:10
15.95v 23:10
15.87v 24:10
End volt 3.96v, Works much better than I had hoped. 12+ hours and still 3.87 volts to go until 12v. Depending on how much the step down would cost I hope to extend this time even longer with the DC volt regulator set to 13v.

While Sitting 12-13v seems to work. The other day I went grocery shopping... yes got some looks. After using I had maxed out the 4x18650 voltage the whole time. Making 8x18650 battery holder so I can get maybe @18v while in usage. Ordered some Cheap power switches and fan controller with dial.. will post once those are done and printed. I hope they take less power than the volt regulator that is taking up to 3v.

All except battery cover does not need supports, they are built into STL, easy remove after print.
4mm FDM Nozzle, 5mm line and parameter width, 0.2mm layer height. Bridge yes

Parts, no affiliate links, just links

They 4x 18650 battery holder case I have no longer is for sale at the same location. This looks to be the same https://www.amazon.com/Vanki-Black-Plastic-Battery-Holder/dp/B0156C0IVW/ref=sr_1_1?dchild=1&keywords=Battery+Holder+Case+w+Wire+for+4+x+18650+14.8V&qid=1586796163&sr=8-1

Future Version will have on/off switch along with speed dial (from digikey), and better battery holder like these https://www.amazon.com/BCP-Plastic-Li-ion-Battery-Batteries/dp/B071K5FCM1/ref=sr_1_2?dchild=1&keywords=Battery+Holder+Case+w+Wire+for+4+x+18650+14.8V&qid=1586796163&sr=8-2

Also unable to locate original seller for the volt regulator but this is the same thing you can get from many places https://www.ebay.com/itm/DC-DC-Adjustable-Step-Down-Power-Supply-Module-Voltage-Current-LCD-Display-Shell/223072968064?_trkparms=aid%3D1110001%26algo%3DSPLICE.SIM%26ao%3D1%26asc%3D225074%26meid%3De397567b09e04c1c8ff17879f7c3eb19%26pid%3D100010%26rk%3D3%26rkt%3D12%26mehot%3Dpp%26sd%3D233524797118%26itm%3D223072968064%26pmt%3D1%26noa%3D1%26pg%3D2047675&_trksid=p2047675.c100010.m2109