There are various environmental, ergonomic, and social issues surrounding currently used respiratory protective equipment (RPE). Most medical grade respirators are currently single use and are either incinerated releasing CO2 into the atmosphere or end up in landfill taking approximately 450 years to degrade. Additionally, many healthcare workers have reported pressure induced discomfort on the nose and cheeks due to donning RPE for prolonged periods, whilst some struggle to find a respirator which fits their face and have to rely on heavy and expensive powered air purifying respirators. Current RPE also acts as a physical barrier obstructing non-verbal communication.

This research considered methods to address the identified issues using a combination of reverse engineering, additive manufacturing, and material science. A LiDAR scanner was used to assess the facial topology of the user. This information was then used to generate a computerised three-dimensional (3D) model of a respirator which is complementary to the user’s facial topology. An extensive literature review spotlighted potential biopolymer materials which show suitable characteristics for use in creating a respirator body that is both transparent and fully degradable under domestic composting conditions. Protocols for testing the transparent materials for their suitability were drawn up and testing of some of the materials and protocols were carried out.