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Project

Fast track development FFP2-FFP3 face masks.

This project started with anticipated shortages in respiratory protective equipment (RPE) at the beginning of the COVID crisis, March 2020, with the challenge to develop an emergency production line of FFP2 and FFP3. The aim was set to achieve local production, with documented and ensured quality. A design brief was drawn from existing respiratory equipment available at UZA and a protocol for emergency validation and quality control was derived from RPE regulations (EN149). Validation methods were constructed in consult with FAGG and FOD-economie. Our team at Antwerp Design Factory immediately started concurrent engineering both modeling, tooling, sourcing and validation. Results comprised validated models for industrial production (curved patterns), fully customizable production line with linear patterns including emergency quality control, with external validation by IFA and Mensura. The customizable line is extremely compact and produces 5000 FFP2 masks in one 38hour shift with 8 operators. Tooling can be realized by 3D prints and laser cutters. Our developments were supported by a scientific advisory board from policy makers, academic and industrial stakeholders. Masks were provided to UZA, ZNA to protect caregivers at COVID units and to the province of Antwerp, to initiated contact tracing.
Date:16 Mar 2020 →  15 Mar 2021
Keywords:PRODUCT DEVELOPMENT
Disciplines:CAD/CAM systems, Machine tools, Manufacturing process planning, Manufacturing processes, methods and technologies, Manufacturing safety and quality, Manufacturing systems, Medical intensive care, Respiratory medicine