In early January, armed with a strong desire to contribute to the fight of the Novel Coronavirus - COVID19, we at Omachron embarked on a journey to develop a mask that could assist individuals in a plethora of professions and unique environmental situations.
We have successfully manufactured two masks to provide the public with additional options for PPE. Our masks were developed by a group of scientists, engineers and technicians with over 300 combined years of scientific experience and expertise in particle separation, air, and water filtration, along with disinfection technology.
The design objective was to develop a mask that could capture 99.0% of bacteria, viruses and other microscopic particles as small as 0.1 micron, both breathed in and expelled out, while being comfortable to wear and as easy to breath through as not wearing a mask. We have launched our unique mask at www.omachrondelta.com.
We documented each step of our development process, providing the public with weekly updates on our progress. In an effort to remind innovators that a product is not an overnight development, but rather an effort of experience, trial, error, and investment of the heart – we have decided to showcase the updates that we provided. We are proud to present to you the step by step process of our development.
As always, we recommend you follow the steps of the WHO. Following the steps below will help to ensure you stay safe.
Wash your hands frequently.
Maintain social/physical distancing.
Avoid touching your eyes, nose, and mouth
Practice respiratory hygiene.
Self-isolate if ill.
April 2, 2020
Testing and Protoyping is Finalized
When the COVID-19 outbreak was initially reported in early January our technical team immediately went to work to design and experimentally develop several designs for optimized personal protective equipment that we felt would be needed in this outbreak.
January through April was dedicated to CAD, rapid prototyping, ergonomic and functional requirements studies, filtration media testing, characterizing physical size vs performance, identifying types of materials to use for construction, and experimentally establishing reliable and repeatable methods of manufacturing. These activities are now complete, specifications for materials have been established, tooling is being made and tested, and the transfer of R&D to manufacturing is in its final stage
April 3, 2020
Medium Size Mask Tools Tested
We completed the first production tools for the medium sized mask which should be suitable for about 65% of the population. We are now doing testing and optimization, as well as establishing quality control protocol. This includes a double inspection to ensure the quality of what we are manufacturing.
April 6, 2020
Medium and Large Size Full Face Mask
We completed the first production tools for the Large sized mask.
This mask should be suitable for people with and without glasses. Please note that this mask won't be suitable for people who need medium or small size and wear glasses but we are experimentally developing designs to meet these needs. Those requiring the small or medium size masks and who wear glasses will have product available in early May 2020.
April 7th 2020
Seal Material and Templates Finalized, Filtration System is Next
We have now completed the experimental development of a full face shield made of polycarbonate which seals to the face of the user using a 0.5 inch thick deformable foam that has been tested for Cytotoxicity-elution (MEM Extraction) per ANSI/AAMI/ ISO 10993-5:2009. We have also tested eight different filtration media and have selected four of these media for commercialization.
One filtration media chosen is a hydrophobic washable PTFE HEPA media which offers 99.03% filtration at 0.1 microns. This is over 5 times more effective than traditional N95 media. The second media offers 99.999% protection at 0.1 microns which is 5,000 times more efficient than traditional N95 media.
The rigid frame of all of our masks combined with a wide, deformable seal provides excellent sealing for a wide range of users and reliable re-use of the mask day in and day out.
The photo adjacent shows two of the masks without their filters attached.
April 10th 2020
Seals.
The Omachron team have been doing a larger number of tests to ensure that our nose/mouth masks, full face masks, and helmet systems properly seal to a wide range of users.
In addition, we have been working on testing of our filter sealing system that ensures complete and visible seals on all filters. This attention to detail, and establishing a100% quality assurance protocol and testing system is critical before we start production so that users can have confidence in our products.
Our unique sealing technology makes the seals of the mask visible for inspection both at the factory and by users after purchase to ensure that their mask is always properly sealed.
April 15th 2020
Child's Size (Small Size) Full-Face Mask
Today we successfully molded our first child's size (small) full-face masks only 5 days after starting the tooling. We now have 3 sizes off tool and plan to start production shortly when we receive production quantities of raw materials.
While children seem to be less effected by COVID-19 virus, we are not willing to take any risks with their health. Many protective masks do not fit children well. A full face mask allows children to see and be seen while preventing them from touching their eyes, nose, mouth and faces. We are also developing masks for kids aged 2 to 5 which is an important challenge with young children because they often have their hands in their mouth and touch their faces which puts them at greater risk of disease. And if the kids want to be astronauts for Halloween - they are all set :)
To summarize where this product is at in it's development:
- All 3 sizes are tooled and being tested;
- The perimeter face seal provides an excellent durable seal and is made of a material which has been tested to be safe on skin by an independent laboratory;
- The Filter cartridge is in it's last stages of development to make it 50% easier to breathe through than N95 masks yet having a superior filter performance of 99% at 0.1 micron, which is the size of the COVID-19 virus.
April 27th 2020
Face Mask Is Off Tool!
We have continued testing and improving our N100 respirator which protects your airways, the N100 full face mask that protects your eyes, face and airways, and other unique PPE in parallel. Both face mask and full face mask will be commercially available soon.
The medium and large face mask sizes are now off tool. We have been using the compact, low cost Omachron plastic injection molding systems. This has allowed us to go from a 3D printed prototype, to a more robust and durable product whose surface finish enables easier cleaning and reuse. We accomplished this task in just a week, and have our third mask coming off tool on Wednesday Apr 29, 2020. The photo shows the 3 sizes of grey colored masks which were prototyped using fused deposition modelling (FDM). Also pictured are our 2 sizes of beige colored masks which are injection molded off tool.
The pandemic has delayed the sale of the Omachron compact, low cost, energy efficient molding machines to the public as we have diverted the available machines to making pandemic supplies. In the next few months, as our ability to supply filtration media, and a variety of protective masks reaches full capacity, we will again be able to make the equipment available for sale. The needs of the pandemic have demonstrated the utility of our process to quickly take 3D printed prototypes into meaningful production quantities of more durable and robust products
May 8th 2020
Face Mask - All 3 Sizes Are Off Tool!
Our amazing new masks are now off tool and we are ramping up for production. These masks feature a number of patent pending features including:
1. Wide, comfortable, durable seals made of closed cell, skin safe cross linked polyethylene foam. This material resists wear and tear, including the harsh chemicals sometimes used to disinfect masks.
2. The seal material can easily be modified by a user to improve the fit to their unique face shape and allow for glasses.
3. The complete seal of this mask eliminates the issues of glasses fogging, a common problem with many masks.
4. The flexible seal design allow users to speak without breaking the seal.
5. The smooth exterior surface of the mask and filter housing are easy to wipe clean as well as keep clean.
6. The mask frame with its comfortable, durable seals, breathable wide straps and easy to use buckles, can be reused for many months or even years. This provides cost savings and minimizes the disposal of personal protective equipment in landfills. Omachron even has a system which allows the mask to be fully recycled.
7. The mask frame and its filtration systems are manufactured locally for local markets. This makes it more sustainable and provides security of supply during emergencies.
Follow us for updates next week disclosing filter design and benefits.
Our amazing new masks are now off tool and we are ramping up for production. These masks feature a number of patent pending features including:
1. Wide, comfortable, durable seals made of closed cell, skin safe cross linked polyethylene foam. This material resists wear and tear, including the harsh chemicals sometimes used to disinfect masks.
2. The seal material can easily be modified by a user to improve the fit to their unique face shape and allow for glasses.
3. The complete seal of this mask eliminates the issues of glasses fogging, a common problem with many masks.
4. The flexible seal design allow users to speak without breaking the seal.
5. The smooth exterior surface of the mask and filter housing are easy to wipe clean as well as keep clean.
6. The mask frame with its comfortable, durable seals, breathable wide straps and easy to use buckles, can be reused for many months or even years. This provides cost savings and minimizes the disposal of personal protective equipment in landfills. Omachron even has a system which allows the mask to be fully recycled.
7. The mask frame and its filtration systems are manufactured locally for local markets. This makes it more sustainable and provides security of supply during emergencies.
May 14th 2020
Colors!
If you’re going through hell, keep going. ~ Winston Churchill
It is a difficult time for a lot of people in these trying days. We hope that you, your family and friends are making the best of it.
The world will slowly re-open, though until there are vaccines or treatments, whether we like it or not, we will need to wear masks to many places we go.
We said to ourselves; If this becomes our new reality for now, we need to make masks that are safe and comfortable. Right now, N95 masks are hot, hard to breathe through, hurt your face and your ears, and can take the joy out of an outing.
With this in mind, we developed our high performance filtration masks to have comfortable seals and a breathing assist system to make breathing easy.
We are trying to make the masks more appealing to a larger demographic with some fun colors - who knows.... this may become a fashion statement. We will share some additional colors in the coming days.
To produce the masks we are using our Canadian made small injection molding equipment, designed to allow small companies to quickly launch new products, to launch our own new products. We are becoming our own testimonial as we quickly ramp up production of our various mask models with a modest investment.
Pictured are the three colors we started with - black, white, and natural as they seem to be the most popular. We will be adding more colors soon. Now you can match the color of your mask to your clothes, or to the occasion. Make it match, make it contrast, make it FUN!
May 20th 2020
Key features of the fan assisted filtration system:
1. The user replaceable filter module includes a durable water repelling Teflon main filter media which provides 99.0% at 0.1 microns, which is smaller than the COVID 19 virus that measures 0.12 microns. This filter can be rinsed with water and reused for approximately 520 hours, around 3 months of regular use.
2. The filter module also incorporates a user replaceable, washable, pre-filter media, which protects the main filter from larger bacteria, viruses, molds, spores, pollen, dust and other airborne particles, thereby extending the life of the main filter.
3. The unique system design filters both the air that you breathe in, and the air that you breathe out, adding protection for you, your family, and your community. Many masks use an exhaust valve or other similar mechanism to release anything that you breathe out into the room.
4. The fan assisted breathing mode makes breathing through the mask as easy as breathing without a mask, and provides a constant stream of fresh air to eliminate moisture and carbon dioxide buildup.
5. The fan assisted breathing modules runs for about 9 hours on a charge, and is rechargeable through a USB port. It can even run and recharge at the same time.
6. The back-pressure main filter and pre-filter combination is so low that even with the fan assist off, breathing with the mask is substantially easier than breathing through a standard N95 mask or N95 respirator.
7. The unique downward facing air intake and exhaust prevents the spray of particles onto your filters if people cough or sneeze. It also prevents rain from getting on the filters.
8. The smooth exterior surface of fan assisted filtration system is easy to wipe clean and keep clean.
9. The fan assisted filtration system can be easily detached from the filter mask for cleaning, maintenance, or replacement. The filtration system is made of a durable, recyclable outer plastic shell. Components, include a replaceable battery rated for 500 to 700 recharge cycles, a fan rated for 20,000 hours of use, and electronics designed for 10,000 hours of use. This filtration system is designed to last for many months, even years thereby, saving money and minimizing the disposal of personal protective equipment in landfills.
May 25th 2020
More colors!
"The best color in the whole world is the one that looks good on you."
- Coco Chanel
Omachron masks are injection molded. This manufacturing process allows us to be more adaptable to consumers' needs and offer masks that are more fun to wear. Our hope is that if the product offers more options, the compliance of wearing the mask will become accepted by many. Chosen by you, mask color will be greatly adapted to your style and environment, who knows.... this may become a fashion statement.
In reading through this post, you have witnessed the great strides that we have made in innovation and technology. An idea comes from inception, and follows through to manufacturability when it is well developed. One ultimate goal of Omachron Science is to continue in the path of our predecessors; moving ideas to products, inspiring innovators to create, and inevitably to change the trajectory of our world for the better. Our hope with this product is to protect, to inspire, and to move forward with innovations that change our world for the better.
We thank you for your continued support, and look forward to meeting you at www.omachrondelta.com where we will update you on variations of our mask.