The SARS-CoV-2 pandemic resulted in shortages of production and test capacity of FFP2-respirators. Such facemasks are required to be worn by healthcare professionals when performing aerosol-generating procedures on COVID-19 patients. In response to the high demand and short supply, we designed three models of facemasks that are suitable for local production. As these facemasks should meet the requirements of an FFP2-certified facemask, the newly-designed facemasks were tested on the filtration efficiency of the filter material, inward leakage, and breathing resistance with custom-made experimental setups. In these tests, the facemasks were benchmarked against a commercial FFP2 facemask. The filtration efficiency of the facemask’s filter material was also tested with coronavirus-loaded aerosols under physiologically relevant conditions. This multidisciplinary effort resulted in the design and production of facemasks that meet the FFP2 requirements, and which can be produced at local production facilities.

Introduction: The current COVID-19 pandemic has caused large shortages in personal protective equipment, leading to hospitals buying their supplies from alternative suppliers or even reusing single-use items. Equipment from these alternative sources first needs to be tested to ensure that they properly protect the clinicians that depend on them. This work demonstrates a test suite for protective face masks that can be realized rapidly and cost effectively, using mainly off-the-shelf as well as 3D printing components. Materials and Methods: The proposed test suite was designed and evaluated in order to assess its safety and proper functioning according to the criteria that are stated in the European standard norm EN149:2001+A1 7. These include a breathing resistance test, a CO₂ build-up test, and a penetration test. Measurements were performed for a variety of commercially available protective face masks for validation. Results: The results obtained with the rapidly deployable test suite agree with conventional test methods, demonstrating that this setup can be used to assess the filtering properties of protective masks when conventional equipment is not available. Discussion: The presented test suite can serve as a starting point for the rapid deployment of more testing facilities for respiratory protective equipment. This could greatly increase the testing capacity and ultimately improve the safety of healthcare workers battling the COVID-19 pandemic.