FlexibleMaskRolley_SIO_Front Mod for Elastic band and HEPA

After spending some time figuring out how to print the FlexibleMaskValvy, out came this wonderfully simpler Rolley design! One thing I learned from the Valvy prints was that for me, using either a cotton round (like for makeup removal) or vacuum cleaner HEPA filter (single layer, cut generously to fit), that small circle didn’t allow enough airflow. It sealed very well on inhale due to the flexible mask and vacuum created, but I felt out of breath just standing there. Obviously you can use a thinner filter, but protection will decrease with it.

Then I discovered his much larger HEPA “snap on” designs, which allow more airflow through a larger filter surface area (even though it still goes through the same small circle, the filter area is the limiting factor). So I found the ultimate mask to be:

FlexibleMaskRolley_SIO_L_TPU.stl (or the size that fits you)

FlexibleMaskRolley_SIO_Front_PLA.stl (PETG or PLA)

FlexibleMaskRolley_SIO_Cover_TPUx2.stl

FlexibleMaskRolley_SIO_Disc_TPUx2.stl

HEPA_Flexible_Mask_Rolley_Cartrdige_80_10_9_22_PLA.stl (PETG or PLA)

HEPA_Flexible_Mask_Rolley_Cover_80_10_9_22_TPU.stl

So you can put a thin piece of cotton on the outlet to protect others from moisture droplets, but the large intake makes breathing easy through even the HEPA filter (vacuum bag) or thick cotton. The valves are awesome to make this function optimally. The “Hexfilter” option works too and is faster and simpler, but without valves this just doesn’t work as well for me.

The only problem building this for me is, something was causing the fit to be wrong on the two circular couplings on FlexibleMaskRolley_SIO_Front_PLA.stl. The standard covers that fit my many TPU printings on Valvy were loose on either PETG or PLA Rolley covers–they just fall off, and naturally so does the heavier Rolley Cartridge. Also, despite how cool the printed strap systems are, I find them hard to use, and they just fall of the mask unless you glue or sew them on. In the end, I much prefer a fixed elastic band system, assuming you have that available as I do.

So this remix is a modification of FlexibleMaskRolley_SIO_Front_PLA.stl to replace the hooks with a slot for attaching the elastic band. I just slip it through, fold it back, and hot glue it on, just takes one minute to do this (once you figure out your fit), and then it’s just instantly available and works. The two files are:

FlexibleMaskRolley_SIO_Front_PET-PLA v3a.stl (only mod is elastic slots)

FlexibleMaskRolley_SIO_Front_PET-PLA v3d.stl (elastic slots, and larger mounting apertures for a tighter fit on the Cover and HEPA_Cartridge).

I also modified FlexibleMaskRolley_SIO_HexFilter_Cover TPU.stl with the slot/elastic change:

FlexibleMaskRolley_SIO_HexFilter_Cover TPU v2a.stl

This pairs with the alternate FlexibleMaskRolley_SIO_HexFilter_Front.stl, and works great but I feel the airflow is a bit low (but much better than just the small circular aperture), and without the valves for an outlet it will get steamy inside. But this is a nice quick mask.

I expect I’ll be criticized for printing the original wrong or something, that’s why the original size and slot are included (v3a), but if anyone else finds their print too loose they can try v3d to see if it helps.

iczfirz, I get the impression my preferred variant is not your favorite (I don’t even see a picture of it), but I think it looks cool and works much better. The trouble is the PLA to PLA friction fit, this is just a tricky design choice. Any ideas to improve the tolerance of the design for easy reliable fit? Not sure how to make a true “snap on” that is airtight and that you have a way to release. “Screw on” does not seem to be an option either. I have wondered if HEPA_Flexible_Mask_Rolley_Cartrdige_80_10_9_22_PLA.stl would print and work in TPU, what do you think?

Many thanks to iczfirz, and hope this helps someone else.