ASSIGNMENT 1 2020

INDUSTRIAL
ENGINEERING
DOCUMENT ON N95 MASK

SUBMITTED TO: SUBMITTED BY:

ASST. PROFESSOR SHUVANKAR PARIDA

NANDKISHORE (BFT/18/771)
BARAIK ABHISHEK SINGH
(BFT/18/379)
2

INTORDUCTION
An N95 mask or N95 respirator is a particulate-filtering facepiece respirator that meets the
U.S. National Institute for Occupational Safety and Health (NIOSH) N95 classification of air
filtration, meaning that it filters at least 95% of airborne particles. This standard does not
require that the respirator be resistant to oil; another standard, P95, adds that requirement.
The N95 type is the most common particulate-filtering facepiece respirator. It is an example of
a mechanical filter respirator, which provides protection against particulates but not
against gases or vapours.
N95 respirators are considered functionally equivalent to certain respirators regulated under
non-U.S. jurisdictions, such as FFP2 respirators of the European Union and KN95 respirators of
China. However, slightly different criteria are used to certify their performance, such as the
filter efficiency, test agent and flow rate, and permissible pressure drop.
The N95 mask requires a fine mesh of synthetic polymer fibres, also known as nonwoven
polypropylene fabric, which is produced through a process called melt blowing that forms the
inner filtration layer that filters out hazardous particles.

N: This is a Respirator Rating Letter Class. It stands for “Non-Oil” meaning that if no
oil-based particulates are present, then you can use the mask in the work
environment. Other masks ratings are R (resistant to oil for 8 hours) and P (oil proof).

95: Masks ending in a 95, have a 95 percent efficiency. Masks ending in a 99 have a

99 percent efficiency. Masks ending in 100 are 99.97 percent efficient and that is the
same as a HEPA quality filter.

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

3

.3 microns: The masks filter out contaminants like dusts, mists and fumes. The
minimum size of .3 microns of particulates and large droplets won’t pass through the
barrier, according to the Centres for Disease Control and Prevention (CDC.)

Material: The filtration material on the mask is an electrostatic non-woven

polypropylene fibre.

Valve: Some disposable N95 masks come with an optional exhalation valve. “The
presence of an exhalation valve reduces exhalation resistance, which makes it easier
to breathe (exhale,)” according to the CDC. 

How do N95 Masks Work?

N95 respirators work by filtering out particles thanks to the structure of their nonwoven
material. Particles get trapped as they are forced to make twists and turns through the dense
network of the material’s fibers, which are as thin as a single micron. Masks also have
electrostatically charged material to further attract particles. As particles build up, the mask
becomes a more efficient filter. However, the buildup also makes the mask more difficult to
breathe through, which is why the masks and filters are made to be disposable.

How are N95 Masks Made?

A medical N95 respirator consists of multiple layers of nonwoven fabric, often made from
polypropylene. The two outward protective layers of fabric, covering the inside and outside of
the mask, are created using spun bonding. Spun bonding uses nozzles blowing melted threads
of a thermoplastic polymer (often polypropylene) to layer threads between 15-35 micrometres
on a conveyor belt, which build up into cloth as the belt continues down the line. Fibres are
then bonded using thermal, mechanical, or chemical techniques. The two outer layers of the
respirator, between 20 and 50 g/m2 in density, act as protection against the outside
environment as well as a barrier to anything in the wearer’s exhalations.
Between the spunbond layers there’s a pre-filtration layer, which can be as dense as 250 g/m2,
and the filtration layer. The prefiltration layer is usually a needled nonwoven. Nonwoven
material is needle punched to increase its cohesiveness, which is accomplished by sending
barbed needles repeatedly through the fabric to hook fibres together. The prefiltration layer is
then run through a hot calendaring process, in which plastic fibres are thermally bonded by
running them through high pressure heated rolls. This makes the pre-filtration layer thicker and
stiffer, so it can be moulded to form the desired shape and stay in that shape as the mask is
used.

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

4

The last layer is a high efficiency meltblown electret (or polarized) nonwoven material, which
determines the filtration efficiency. Meltblowing is a process similar to spunbonding, in which
multiple machine nozzles use air to spray threads of melted synthetic polymers onto a
conveyor. However, these fibres are much smaller, as less than a micron wide. As the conveyor
continues, the threads build up and bond by themselves as they cool, creating the fabric.
However, sometimes meltblown fabric is also thermally bonded to add strength and abrasion
resistance, although the material then begins to lose some of its fabric characteristics.

The full respirators are made through converting machinery, which combines the layers
through ultrasonic welding and adds straps and metal strips to adjust the mask over the user’s
nose. The respirators are then sterilized as a last step before being shipped.

MAJOR PROBLEMS FACED USING THE MASK

Elderly people, people with lung or

heart conditions, and women in the
later stages of pregnancy may already
have reduced lung volumes or
breathing issues. 

A person should take a break from

using a N95 mask if he/she feels
uncomfortable. Elderly, pregnant
women and people with severe lung
or heart problems who have difficulty
breathing at rest or on exertion should
consult their doctor as to whether
they should use the N95 mask. 

Women in the 2nd and 3rd trimesters of pregnancy may already have reduced
lung volumes or breathing issues. They should stop using a N95 mask if they feel
uncomfortable.

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

5

N95 masks filters out 95% or more of small particulate matter from the air–
including the virus.But in filtering those particles, the mask also makes it harder to
breathe. N95 masks are estimated to reduce oxygen intake by anywhere from 5
to 20 percent. That’s significant, even for a healthy person.

Not only can the masks cause dizziness and lightheadedness but they can also
damage the lungs. For patients who already have respiratory complications,
wearing a mask could be life-threatening. Then again, without a mask, heading
out in public to stock up on groceries could also be a death sentence.

Splashes and sprays of biological fluid on the faceseal area can diffuse inside the
respirator. Furthermore, numerical simulations have shown that migration of
liquids from the outer surface of the respirator to the inner surface is theoretically
possible due to diffusion and capillary action 

One concern is that variations in respirator shape could make some devices more
susceptible to biological fluids reaching the facial skin in the oronasal region,
ultimately increasing the risk of disease transmission. Many surgical N95
respirators have a rigid structural design (cup-shaped or trifold) that prevents the
inner surface of the respirator from coming in contact with the user’s face.

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

6

On the other hand, some designs such as the flat fold models appear less rigid and
may allow the inner surface of the respirator to touch the face during breathing.
In this scenario, the user may be exposed to biological secretions that reach the
inner surface of the mask.

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

7

Some structural designs such as flat fold models may collapse against the mouth
and transfer infectious organisms to user’s face. It is hypothesized that the
internal surface of flat fold respirator models might touch a user’s face when a
significant change in rigidity occurs during heavy breathing. 

The bi-fold and trifold designs, which are flexible, appear to undergo shape
change during heavy breathing conditions. 

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

8

STUDY OF THE USER AND HOW IT IS DONE

This study consisted of two parts.

Part 1 of the study investigated
training of
predictors based on machine learning
algorithms. The predictors were in
the form of
binary classifiers that answer fit/unfit
given a set of facial measurements.
Part 2 of
the study focused on a low cost 3D
scanning system to extract facial
measurements.
It investigated if a system
consisting of a hand-held projector,
web-cam, and a

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

9

notebook computer could provide

sufficiently accurate facial
measurements for the
predictors. The fit testing process
does not necessarily require
automated facial
anthropometry, but a low-cost
solution is attractive because
structured light 3D
scanning is quicker and less intrusive
than manual facial anthropometry.
This study consisted of two parts.
Part 1 of the study investigated
training of
predictors based on machine learning
algorithms. The predictors were in
the form of

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

10

binary classifiers that answer fit/unfit

given a set of facial measurements.
Part 2 of
the study focused on a low cost 3D
scanning system to extract facial
measurements.
It investigated if a system
consisting of a hand-held projector,
web-cam, and a
notebook computer could provide
sufficiently accurate facial
measurements for the
predictors. The fit testing process
does not necessarily require
automated facial

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

11

anthropometry, but a low-cost

solution is attractive because
structured light 3D
scanning is quicker and less intrusive
than manual facial anthropometry.
This study consisted of two parts.

 Part 1: the study investigates the training of predictors based on machine

learning algorithms. The predictors were in the form of binary classifiers
that answer fit/unfit given a set of facial measurements.
 Part 2 of the study focuses on a low cost 3D scanning system to extract
facial measurements. It investigated if a system consisting of a hand-held
projector, web-cam, and a notebook computer could provide sufficiently
accurate facial measurements for the predictors.

The
fit testing process does not necessarily require automated facial
anthropometry, but a low-cost solution is attractive because structured light
3D scanning is quicker and less intrusive than manual facial anthropometry.

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

12

The average data of a face is shown below:

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

13

SUGGESTED CHANGES
Fit issue:
Since the masks are made of free size the whole fit of the mask depends upon the metal piece
that is attached on top of the nose which was not sufficient, and even if it was able to provide
proper fit on the upper part there would still be issues in the part that would be on the chin.

So the major changes that we suggested to solve this issue was to attach a simple PIPING
instead of that metal piece in the mask on the both top and bottom part which would provide a
proper fit with comfort.

PIPING

Inadequate supply of air:

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

14

Due to the way and the material that is used in the making of the mask it reduces the supply of
air that causes problems in breathing. This causes a great deal of problem in the elderly and the
infants.

So the change that could be made to deal with this problem is we can add a valve in the mask
which will allow a proper flow of air from one place and to make sure that no foreign particles
enters the mask we will add a filter paper that will stop it from entering. This will ensure a
proper supply of air with no foreign particle entering inside the mask.

VALVE

In today’s scenario:
Looking at today’s scenario when the whole world is
facing the Pandemic we are looking towards different
alternative to save ourselves from the virus. The mask
only provides safety from the virus to nose and the
mouth.

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

15

The eyes are still unprotected, and it is advised by the health authorities that we have to save it
also, so for that the one change that could be made is we can add an plastic protective film that
will protect our eyes from the virus.

REFERENCE:
 https://www.ncbi.nlm.nih.gov/pubmed/15354730
 https://va.ecitizen.gov.sg/CFP/CustomerPages/NEA_google/display
result.aspx?
MesId=1069078&Source=Google&url=va.ecitizen.gov.sg

 https://www.popularmechanics.com/technology/design/a32156952/stanford-
redesign-n95-face-mask-covid-19/

 https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7111508/

 https://sci-hub.tw/https://doi.org/10.1080/15298669291360283#

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22

16

 AN ASSESSMENT OF CRITICAL ANTHROPOMETRIC DIMENSIONS

FOR PREDICTING THE FIT OF A HALF- MASK RESPIRATOR

NATIONAL INSTITUTE OF FASHION TECHNOLOGY 18-22