May/June_AMP_Digital

A D V A N C E D M A T E R I A L S & P R O C E S S E S | M A Y / J U N E 2 0 2 0 8 0 3D PRINTSHOP Medical workers can now get mass customized, 3D-printed protective eyewear for free. Courtesy of Fitz Frames. 3D-PRINTED METAL FILTERS EXTEND LIFE OF RESPIRATORS Reusable porous metal filters 3D printed with technology from ExOne, Huntingdon, Pa., were manufactured to fit inside a plastic respirator car- tridge designed by the University of Pittsburgh. ExOne’s binder jetting tech- nology is a high-speed form of 3D print- ing that can produce metal parts with specific porosity levels that can effec- tively filter out contaminants while al- lowing airflow. ExOne has 3D printed respirator filters in two metals—copper and 316L stainless steel—and a range of porosity levels for use inside a unique cartridge designed by the Mechanical Engineer- ing & Materials Science department in Pitt’s Swanson School of Engineering. Initial testing for airflow and filtration efficiency is currently underway, and the filters are being optimized with the goal of adhering to an N95 respirator standard. “Our team has been working ur- gently to expedite this promising and reusable solution for medical person- nel on the frontlines of fighting the COVID-19 pandemic,” says John Hart- ner, ExOne CEO. “Once approved, we can print these filters in a variety of siz- es for respirators, ventilators, anesthe- sia masks, or other equipment.” exone. com, engineering.pitt.edu. REUSABLE 3D-PRINTED FACE MASKS Rowan University engi- neering and medical students have developed a prototype for a durable, lightweight, reusable face mask to aug- ment the supply of masks during the current shortage of personal protective equip- ment (PPE) due to the COVID-19 outbreak. The mask is provided “as-is” and pri- marily acts as a mechanical barrier. It is not a replacement for N95 masks. Developed in collaboration with medical professionals, the mask pro- totype may serve in clinical and field use. If printed, used, and maintained correctly, the mask provides a durable, reusable mechanical barrier. The prototype provides two com- ponents: a contoured mask and filter housing. The contoured mask may be more closely molded to the user’s face by submerging the edges in hot water and pressing it to reform the shape against the face. The replace- able nonwoven filter materials recom- mended for the filter housing are wide- ly available. A team of Rowan University faculty and students is racing against the cur- rent pandemic to create 3D-printed face masks to address the shortage of PPE for South Jersey’s health care workers and emergency responders. Their de- signs are now available for public use. rowan.edu/mask. REIMAGINED CUSTOM GLASSES Fitz Frames, California makers of kids’ glasses, has shifted their manu- facturing to focus on making protective eyewear for medical personnel. The 3D-printed glasses are manufactured in Ohio, through the Youngstown Business Incubator group. The goal is to get this eyewear into the hands of medical pro- fessionals as quickly as possible at no cost to them. Donations offset the costs. Medical personnel can sterilize the metal filters from ExOne for repeated reuse, eliminating waste. These 3D-printed masks come in three sizes, all with the same size filter housing. Courtesy of Rowan University. An augmented reality iPhone app makes it possible to try on styles and colors virtually, upload the lens pre- scription, and then order frames of ex- actly the right size. The glasses, offered in both prescription and non-prescrip- tion options, are custom fitted, thanks to the front-facing camera and app technology, which measures over 1000 points on each face. The frames are additively manu- factured using selective laser sintering (SLS) and a bed of polymer powder to build up each layer. As a bonus, these frames cannot break at the traditional fail point—the hinge—because there are no metal parts. fitzframes.com