3D Printed Face Mask – School Fab Lab

THE MONTANA MASK

The Montana Mask is a highly effective filtration mask. It’s 3D printable and the design files are free for public use. It can be sanitized and reused. Although not approved by the FDA or NIOSH, the mask has been rigorously tested. The level of protection is customizable, depending on which material you use for the filter.

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We like this mask because it uses less N95 filter material which is currently hard to find and also there is a method for recycling your old filters-

I downloaded the files and reviewed them in Thinkercad first for fit.

Then I uploaded to MakerBot print software as I am going to print my mask on my replicator + 3D printer.

For our printing process, we have used: 

30% infill

Suggested height layer of  .2 mm

Built without supports

Print time was 3h 23min

We like this mask because it uses less N95 filter material which is currently hard to find and also there is a method for recycling your old filters- see below

ASSEMBLY INSTRUCTIONS video

1. A demonstration of how you can turn a one-time-use surgical mask into multiple surgical masks!
2. How to use a window seal for a better fit and seal on your Montana Mask.
3. Dusty Richardson, MD shows how the Montana Mask can be better shaped to your face with hot water.
4. A how-to for installing additional nose piece gasket.

Shopping list  

1. Weather Stripping (amazon link) 
2. N95 face mask (amazon link) Or alternative filter – HEPA Cloth Vacuum Bags (amazon link) 
3. Elastic band (amazon link)

Summary

Printing the Files

• Two .stl files need to be printed per mask and are located at www.makethemasks.com
• We suggest PLA material, but others such as ABS will work
• Takes 3-6 hours and varies printer to printer
• Designed to be printed without supports
• Print an array if possible, source file is included if one would like to modify
• Designed for Adult Large, scale to 90% or less for smaller masks

Making the Mask

• Sand around the edge are touching the face with 200 + sandpaper
• For added seal, a self-adhesive gasket material (Weatherseal “D” Profile 5/16 inch wide found

at a local hardware store) can be applied on the inside edge of the masks

• A second gasket is applied underneath the first gasket around the nose area. 7 inches seems to work best
• Fasten elastic cord to the attachments and adjust to desired tension
• Elastic cord, string, straps, or any variation can be used as ties

Placing Filter

• Existing clinical masks can be used as filter patches (surgical masks for surgical, and N-95

masks for better protection) by cutting them into 2.5 in squares. You can get 6 filters from one mask

• Place filter material on the inside of the mask and fasten by pushing holding ring and filter

together into space

Aseptic Technique

• These masks are reusable, but each person should have their own
• Masks can be cleaned and disinfected by soap and water as well as disinfectant agents
• Practice good hygiene by washing hands before and after changing filters and removing mask
• Clean mask often, change filter often

*Special Thanks to Dusty Richardson, Colton Zaugg, Spencer Zaugg, as well as Billings Clinic for the ideas, designs, and implementation

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