ABSTRACT
Additive manufacturing is a rapidly evolving technological field, beyond he simple application of 3D printers, leading to an entirely new means of designing and manufacturing objects, paving the way for novel and unexplored possibilities. It is currently used in the production of mechanical components and tooling, medical and surgical implants and, also, to facilitate surgical design. The advantages stemming from this technology should be facilitated to combat the COVID-19 pandemic. With cases of respiratory failure and respiratory distress globally soaring and unavailability of standard automated ventilators in certain regions, the need to meet this demand is crucial. In this context, the research team considered it appropriate to move towards finding a solution to the problem of shortage in respirators in health systems worldwide. Having originally received plans for 3D printing from the University of Illinois, which produced disposable mechanical respirators with this technology, the possibility of optimizing and producing them at UNIWA was explored. The CAD files were analyzed in order to evaluate their printability resulting in partial redesign in order to limit dimensional variability, acceptable surface finish and make the printing process generally easier, faster, and less expensive. In addition, these modifications make the parts more suitable for casting, if high output is required. Metallic and thermoplastic composite respirators were produced and then tested in real operating conditions, i.e. with oxygen supply resembling a hospital environment. The initial results are considered positive, both in the quality of construction and in their performance. Furthermore, combination ofmanufacturing technologies is assessed, aiming at high output production. © 2022 American Institute of Physics Inc.. All rights reserved.