Low cost centrifugal melt spinning for distributed manufacturing of non-woven media.

Centralized manufacturing and global supply chains have emerged as an efficient strategy for large-scale production of goods throughout the 20th century. However, while this system of production is highly efficient, it is not resilient. The COVID-19 pandemic has seen numerous supply chains fail to adapt to sudden changes in supply and demand, including those for goods critical to the pandemic response such as personal protective equipment. Here, we consider the production of the non-woven polypropylene filtration media used in face filtering respirators (FFRs). The FFR supply chain's reliance on non-woven media sourced from large, centralized manufacturing facilities led to a supply chain failure. In this study, we present an alternative manufacturing strategy that allows us to move towards a more distributed manufacturing practice that is both scalable and robust. Specifically, we demonstrate that a fiber production technique known as centrifugal melt spinning can be implemented with modified, commercially-available cotton candy machines to produce nano- and microscale non-woven fibers. We evaluate several post processing strategies to transform the produced material into viable filtration media and then characterize these materials by measuring filtration efficiency and breathability, comparing them against equivalent materials used in commercially-available FFRs. Additionally, we demonstrate that waste plastic can be processed with this technique, enabling the development of distributed recycling strategies to address the growing plastic waste crisis. Since this method can be employed at small scales, it allows for the development of an adaptable and rapidly deployable distributed manufacturing network for non-woven materials that is financially accessible to more people than is currently possible.

Máscaras do Bem: An analysis of face-mask performance from a volunteer mask-making initiative in Ribeirão Preto, Brazil.

OBJECTIVES: This study examines the response of a group of volunteers in Ribeirão Preto, Brazil, as the city faced an unprecedented demand for face masks during the onset of the COVID-19 crisis in 2020. The performance of artisanal-produced masks was compared with industry equivalents. STUDY DESIGN: Case report with comparative testing. METHODS: A comparison was made between two parallel projects that produced single-use masks for healthcare workers and reusable masks for the community. Mask samples were tested for filtration efficiency (FE) and breathability (pressure drop). RESULTS: Results for FE averaged 40-60% for healthcare masks and 10% for community masks; both types of masks were tested for particle sizes of 0.3 â€‹µm. CONCLUSIONS: While performance was inferior to standard comparators, the masks investigated in this study afforded a level of protection in the absence of alternatives, especially in non-aerosol generating contexts. The findings of this study are useful for communities with limited resources in other developing countries. In addition, insights can be gained from the experiences in Ribeirão Preto in terms of how to respond to future health emergencies.

Applying heat and humidity using stove boiled water for decontamination of N95 respirators in low resource settings.

Global shortages of N95 respirators have led to an urgent need of N95 decontamination and reuse methods that are scientifically validated and available world-wide. Although several large scale decontamination methods have been proposed (hydrogen peroxide vapor, UV-C); many of them are not applicable in remote and low-resource settings. Heat with humidity has been demonstrated as a promising decontamination approach, but care must be taken when implementing this method at a grassroots level. Here we present a simple, scalable method to provide controlled humidity and temperature for individual N95 respirators which is easily applicable in low-resource settings. N95 respirators were subjected to moist heat (>50% relative humidity, 65-80°C temperature) for over 30 minutes by placing them in a sealed container immersed in water that had been brought to a rolling boil and removed from heat, and then allowing the containers to sit for over 45 minutes. Filtration efficiency of 0.3-4.99 µm incense particles remained above 97% after 5 treatment cycles across all particle size sub-ranges. This method was then repeated at a higher ambient temperature and humidity in Mumbai, using standard utensils commonly found in South Asia. Similar temperature and humidity profiles were achieved with no degradation in filtration efficiencies after 6 cycles. Higher temperatures (>70°C) and longer treatment times (>40 minutes) were obtained by insulating the outer vessel. We also showed that the same method can be applied for the decontamination of surgical masks. This simple yet reliable method can be performed even without electricity access using any heat source to boil water, from open-flame stoves to solar heating, and provides a low-cost route for N95 decontamination globally applicable in resource-constrained settings.

Review of the Breathability and Filtration Efficiency of Common Household Materials for Face Masks.

The World Health Organization and the United States Centers for Disease Control have recommended universal face masking by the general public to slow the spread of COVID-19. A number of recent studies have evaluated the filtration efficiency and pressure differential (an indicator of breathability) of various, widely available materials that the general public can use to make face masks at home. In this review, we summarize those studies to provide guidance for both the public to select the best materials for face masks and for future researchers to rigorously evaluate and report on mask material testing. Of the tested fabric materials and material combinations with adequate breathability, most single and multilayer combinations had a filtration efficiency of <30%. Most studies evaluating commonly available mask materials did not follow standard methods that would facilitate comparison across studies, and materials were often described with too few details to allow consumers to purchase equivalent materials to make their own masks. To improve the usability of future study results, researchers should use standard methods and report material characteristics in detail.