from the editor
from the editor
Molding Devices to Humans : A More Efficient Way of Testing PPE
What has been fascinating to watch is the innovation that has sprung from the COVID-19 pandemic .
A team at Sandia National Laboratories has developed a faster and more comprehensive way of testing personal protective equipment ( PPE ). The basic principle : modeling a device to fit the human form and human behavior .
When COVID-19 hit , PPE testing became an urgent need . In March 2020 , when the country went into lockdown , many people turned to Sandia for PPE testing support . They were trying to bring new masks to the market , provide quality assurance for imported masks and vet cleaning processes for reuse of single-use PPE .
“ Whether using in-house or commercial filter test systems , we found the testing process was very time-consuming and not as efficient as it could be ,” says Michael Omana , an aerosol scientist at Sandia .
The team , which includes engineers Todd Barrick and Brad Salzbrenner , was determined to find a better solution . They were trying to think of ways that respirators could be tested rapidly , not destructively , and have other testing capabilities introduced , including going beyond testing the filtration material .
The current method for testing PPE involves attaching a mask to a flat plate inside a box , using hot wax or putty , and then introducing a test aerosol to measure penetration levels . To achieve certification from the National Institute for Occupational Safety , 20 masks of the same type must be tested . That has proven to be time-consuming . During the pandemic , it resulted in a massive testing backlog for the respirator industry . However , the team said time was just one issue . The current process doesn ’ t consider other factors in mask use .
“ All you are doing is testing the filter media itself ,” explains Barrick . “ It doesn ’ t test geometry , how the respirator fits on a face , how it ’ s moved on and off multiple times , how the straps perform , how the nose bridge performs , how the mask can wear over time .”
There was also the issue of reuse of PPE . With such a worldwide shortage , frontline workers were forced to reuse respirators designed for single use . However , there was no standard method of testing mask reuse .
“ I think there were a lot of lessons learned with everyone suddenly looking at what the industry standards were ,” Omana says .
The team had a new idea to speed up the process and make it more effective . They started by creating a model of a human face that could be loaded into a commercial filter test system .
“ We wanted quicker testing and to look at more features , like how does the mask fit on a face ,” Salzbrenner says . “ We used 3D printing capabilities to make it more pliable , like skin .”
Once the mask is affixed to the form , the tester applies pressure to give an airtight seal and then introduces the aerosol . But the team agreed even more could be done . The current testing standards don ’ t consider how a real person might wear a mask and the gaps or flaws that a mask might present in real-life conditions . So , they developed a more complex version using a complete human head .
Once the mask is affixed , the entire head is put in an airtight box that is then placed in the machine and tested , allowing for a more
Michael Omana affixes a mask to the current generation of the 3D printed head while testing at Sandia National Laboratories . Courtesy of Craig Fritz / Sandia National Laboratories
natural flow of air over the mask and what they believe is a more realistic picture of mask performance . The mechanical engineers on the team then took things one step further to help address the reuse of PPE , something there is currently no testing standard for .
“ We developed the chamber version to automate donning and doffing ( the putting on and taking off of an item ) to test respirator function over time , a predominant factor in wear on a mask . It also mimics how a mask is set on the face and shows you any gaps that air and particles can get past ,” Salzbrenner says .
The team said this can be used in addition to the other testing models they created or developed to be an all-in-one tester . All of which would be a big advance in the way PPE is tested in the U . S . as well as other countries .
“ I call it holistic testing ,” Omana says . “ It considers all the aspects of the mask . Aerosols are like electricity and take the path of least resistance . Even if the filter media is doing great , if another subcomponent is failing , the PPE can be rendered useless . Current testing standards do not quantitatively test PPE in a real-use capacity . This emulates the real-world use of PPE .”
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6 august 2023 • www . healthcarehygienemagazine . com