The Custom-Fitted Face Mask
- M. M.
" Easily the most comfortable respirator I have worn. Lightweight and does not muffle speech like some masks do. "
- N. G.
" It's hard to find a mask that fits me. I've had to wear tape to seal around my nose before. This mask does not fog my glasses. "
I served as an essential worker during the peak of COVID-19 making protective equipment for medical workers in NYC.
Through conversations with medical pros on the front lines, my colleague Jared and I discovered that most protective equipment fits poorly, which causes severe discomfort and significantly reduces effectiveness.
In response, we founded AOP Inc. and created the custom-fitted Air 95 face mask to deliver the most comfortable, most secure face mask to the heroes who need it.
Take a look into the design process below!
current face mask products
initial ideation
Quick Backstory
design brief: design a face mask focusing on comfort, protection, and human-centered usability.
address the improper fit problem with a better fitting face mask for everyone
design brief: utilize 3D scanning and 3D printing to create a custom-fit face mask.
ethnographic research
and user testing:
in April 2023, 14 users participated in a product trial and
gave us their feedback on how to improve the mask.
visualization of research results
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design objective:
make a custom-fit face mask for all face shapes and markets.
focus on the following objectives to do so:
1. max comfort + protection 2. sustainable + scalable 3. great ux / look
detail sketches
air gasket sketches
filter attachment design
organic form SOLIDWORKS start
collaborated with AOP Inc. Lead Engineer Jared West to create Air 95 SOLIDWORKS product stack
STANDARDIZED
cap gasket part
STANDARDIZED
mask body part
strap anchor
on cap part ( UPDATE )
silicone injection
mechanical lock points
STANDARDIZED
cap gasket silicone
injection mold
STANDARDIZED
mask body
silicone injection mold top
CUSTOMIZED
mask body
silicone injection mold bottom
( CUSTOM PAD )
first SLS 3D printed
STANDARDIZED parts + filter
first photoshoot with completed mask +
CUSTOM-FITTED silicone pad
custom-fitting technology
unique face
data points
Air 95 Face Scan App collects thousands of your data points in a single picture to automatically generate a perfectly fitting mask for you.
autoclave
or wipe down
sterilization
new filter
replacement
used filter
disposal
Reusable, Sustainable, & Cost-Effective
individual use
View Patent
organizational use
product comparison
custom-fit manufacturing : 65% standardized molds + 35% customized molds
click page to visit company website!
thank you for viewing!
click a picture below to see more design!
Oishii Berry
- vertical farming design
- industrial design
- robotics & process design
- tool design
- instruction manual design
- project management
- full-time corporate design
Palma
- eatware made from palm leaf
- industrial design
- brand creation
- partnered with India-based business
- won India-based fundraising
Freelance Designs
- consumer product design
- prototyping
- product photography
- client management
ID Drawings
- form study
- personal speed challenge
About Matthew Kelley
- bio
- 2024 resume
- contact info