Airways protection for healthcare personnel

free project Gerlando Maggio – Facebook page: Servizi Informatici



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The global emergency we are experiencing during this period has made suffering the entire national health system, consequently to protect the whole healthcare personnel became an absolute priority and, thanks to the help of 3d printing technology , it is now possible to increase defense systems to protect all health workers in the field.

For the hospitalized patients have been already modified the Decathlon masks, adapting those to respiratory purposes.

Meanwhile for healthcare personnel, it has become extremely difficult to get the dpi classical systems available and nevertheless very difficult to get high protection filters too, especially in the southern areas.

Furthermore, the above systems are single-use and each filter must be replaced at a certain number of hours.
Provided that nowadays the real difficulty is in finding dpi related to their daily disposable consumption, I thought of a solution conceived for individual use, multipurpose and, most important, with filters easily available in hospitals.

The filters that can be used in an emergency situation are those already used in fans, filters that are working to 99.9% also against viral agents, including coronavirus.
Furthermore, the duration of the filter in continuous use is over 24h.

For total protection, stating that the healthcare personnel is always in close contact with the infected, snorkeling mask is an excellent protection since insulates the whole visage surface, perfectly protecting face and airways.
For the very first prototype, after a deep study across all models available in the market, I selected a mask manufactured by SEAC, model named  “Magica”,  and purchased a fan filter.

After a quick study on the technical aspects of this specific mask, I have redesigned the adapter in  between the mask and the filter, which has been printed in 3D technology, obviously reconsidering the appropriate measurements, through a solid and robust material with watertight connection.

After repeated tests, has been verified that the air breathed by the user was perfectly filtered by the system.

Thanks to the highly professional design made by SEAC and its exclusive patented system of separate circulation of the inhaled and exhaled air, the inner circulation air flows of this mask are perfectly matching with this specific purpose.

Mask is also provided with EN136 certification which guarantees the non-accumulation of CO2, very important considering the intensive use in several consecutive hours.

The protective device obtained could fall into those devices expressly reported into Art. 15 of the Law Decree of 17/03/2020 “Extraordinary provisions for the production of surgical masks and personal protective equipment”.

The 3D printed adapter is compatible with all SEAC full-face masks model: Magica, Unica and Libera, all models which are currently easily available on the various online stores.

Anyhow I decided to release the file for free since not created for commercial purposes.

If we all do little together we can do a lot.

To complete the entire set are needed

  • 1 SEAC mask model Magica, Unica or Libera, available on the various online stores
  • 1 filter for fans, make sure filter is antibacterial and antiviral with 22mm connector
  • 1 adapter, under the stl file for printing
  • silk patch (or Teflon tape )

FILE STL covid19tfpmask:

Click here to download the stl file

Tips for printing

The material used is PLA. Print settings could be different since those are depending on the material used and the printing machine as well.

To print the GEEETECH brand PLA with Ender 3 pro printer, I used the following parameters:
flat 60 ° – infill density 30 – triangle pattern – nozzle 205 ° – layer height 0.16 – wall thickness 1.2 – wall line count 3 – top thic 0.84 – top layers 6 – botton thick 0.84 – botton layers 6 – speed 50.0 mm/s


If inserted, remove the mouthpiece from the mask.

Once the molded adapter is terminated, to get a complete watertight integrity, and not to damage the surfaces, wrap 3 turns of silk patch (or Teflon tape) at the base of the adapter. Subsequently leave the patch protrude a few millimeters out from the workpiece (as in the photo)

Same operation, 2 turns of silk patch to the filter connector (diameter 22mm)

Insert the adapter into the mask, push it until you feel adapter is blocked.

Insert the filter into the adapter, in a circular motion (it is not necessary to insert it all), and stop as soon as you feel that it is blocked in total security.

It is not necessary to apply too much effort since weight of the filter is minimal.

The mask is now ready.
To test the water-tightness of the parts, during the inhalation phase it is necessary to “plug” the filter inlet and verify the relevant suction effect generated inside the device, which is almost immediate.

To replace or remove the filter, use the same precautions applied during the assembly process, just slowly rotate the filter and remove it from the adapter.

I thank SEAC for the prompt and pro-positive availability and embrace the project.

Official SEAC channels:

andràtuttobene #coronavirus #emergency #sicily #italia #3dmaker

N.B. however, it is necessary to remark that the SEAC masks have been designed, manufactured and CE marked for snorkeling purposes only and therefore the Company is not responsible for different uses.

All changes, as far as tested, are the responsibility of the end user.

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