3D printed mask extenders as a supplement to isolation masks to relieve posterior auricular discomfort: an innovative 3D printing response to the COVID-19 pandemic

Abstract

Purpose Many commonly used mask designs are secured by elastic straps looping around the posterior auricular region. This constant pressure and friction against the skin may contribute to increased wearer pain, irritation, and discomfort. The purpose of this work is to report a modified 3D printed mask extender to alleviate discomfort and increase mask wearability by relieving posterior auricular pressure from isolation masks. Methods Our institutional review board designated this project as non-human research and exempt. As part of resourcing 3D printing laboratories along with individual 3D printers to provide resources to healthcare workers, mask extenders were printed to relieve posterior auricular pressure from individuals wearing isolation masks. The authors modifed an existing mask extender, increasing its length with accompanying peripheral rungs for isolation mask securement. 3D printing was performed with Ultimaker S5 (Ultimaker B.V.; Geldermalsen, Netherlands) and CR-10 (Creality3D; Shenzhen, China) 3D printers using polylactic acid filaments. The author’s modified extended mask extenders were printed and freely delivered to healthcare workers (physicians, nurses, technologists, and other personnel) at the authors’ institution. Results The final mask extender design was printed with the two 3D printers with a maximum 7 straps printed simultaneously on each 3D printer. Mean print times ranges from 105 min for the Ultimaker S5 printer and 150 min for the CR-10. Four hundred seventy-five mask extenders were delivered to healthcare workers at the authors’ institution, with the demand far exceeding the available supply. Conclusion We offer a modification of a 3D printed mask extender design that decreases discomfort and increases the wearability of isolation mask designs with ear loops thought to relieve posterior auricular skin pressure and ability to control strap tension. The design is simple, produced with inexpensive material (polylactic acid), and have been well-received by healthcare providers at our institution.

Mask Design for Life in the Midst of COVID-19

“…discomfort to the user [23]. The upper border of the mask is not sealed with the face causing the exhaled exhaust gas to flow upward while wearing a mask.…”

“…For example, wearing a mask often causes discomfort, such as increased respiratory resistance and skin irritation on the contact surface between the face and the mask [22]. The elastic straps of the masks will cause pressure and friction constantly in the posterior auricular region and cause pain and discomfort to the user [23]. The upper border of the mask is not sealed with the face causing the exhaled exhaust gas to flow upward while wearing a mask.…”

Masks for COVID‐19

“…In addition to the use of cloth masks, researchers, and manufacturers have also paid attention to fabricating personal protective equipment (PPE), including masks and their components, by utilizing 3D printing (namely, Additive Manufacturing (AM)) to alleviate the shortage of surgical masks and respirators. [ 122 , 123 , 124 , 125 , 126 , 127 , 128 , 129 ] 3D printing is a novel and innovative rapid prototyping technology, and it can be used to fabricate complex geometric structures which connot be easily fabricated through traditional manufacturing process. [ 130 , 131 ] There are a host of various materials that can be used as the base material in 3D printing, such as polyamide (PA) composite, acrylonitrile butadiene styrene (ABS), nylon PA, polylactic acid (PLA), ULTEM (polyetherimide), and thermoplastic polyurethane (TPU).…”

Beyond Pathogen Filtration: Possibility of Smart Masks as Wearable Devices for Personal and Group Health and Safety Management

“…In this section, we further explore what other biosignals can be measured and what applications can be used through a smart mask as a wearable device for health care and safety. In addition, we argue that it is critical to reduce the posterior auricular (back of the ear) discomfort and pain caused by long-term wearing of the mask, as witnessed by a mask frame extension that supports an ear strap introduced recently [ 38 ]. In consideration of the ear strap frame, we would like to present a viewpoint on the extension of the application of the smart mask and its potential as a biosignal measuring device.…”