Exploring how each layer within the mask could fit harmoniously with the face was an essential first step to the design process.
Given the nature of the product and its use, cleaning the mask is also a key feature for users. Utilising a modular design for disassembly ensured that all areas could be accessed and cleaned effectively.
The Realise team used three-dimensional head modelling to ensure optimal face fitting alongside vent positioning to improve breathability and minimise leakage around the face seal.
Changing the mask door mechanism to a single latch and adding extra fixing points improved the rigidity of the product and sealing. From here, we were able to re-design the mask door opening operation without causing discomfort.
Using our prior experience with both safety devices and health care products, we were able to work closely with commercial development laboratories to speed up and reduce risk throughout the process. In addition, we ran a series of tests on prototype masks to assess filtration quality, seal, and fit and adjust where necessary to improve performance.
To increase the longevity of the filters, the design team carefully considered the construction and fitting of the outer AirSkin®, exploring a variety of materials and processes such as 3D knitting. In addition, textile development ran alongside the enclosure design, a specialised discipline our team has experience with.
The design team embedded the Airhead branding into the design process was just as important as the technical delivery, and in this case, the logo featuring AirSkin® became the ideal place.
Onward into manufacture, the Realise team, created all technical files and met with suppliers directly to help support Airhead on the final leg of their journey. The Airhead mask is patent-pending across the UK and Internationally, registered in the UK, US, China, and the EU. The outcome of all the hard work is a sophisticated, customisable, comfortable Mask that has been designed to last.