Case study into the successful emergency production and certification of a filtering facepiece respirator for Belgian hospitals during the COVID-19 pandemic

[Display omitted] •Design and deployment of a nimble manufacturing system of filtering facepiece respirators under pandemic conditions.•Additive manufacturing as a resilient manufacturing method.•Development of a 3D-printable exhalation valve model, validated with seven different 3D-printing materia...

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Bibliographic Details
Published in:Journal of manufacturing systems 2021-07, Vol.60, p.876-892
Main Authors: Vanhooydonck, Andres, Van Goethem, Sander, Van Loon, Joren, Vandormael, Robin, Vleugels, Jochen, Peeters, Thomas, Smedts, Sam, Stokhuijzen, Drim, Van Camp, Marieke, Veelaert, Lore, Verlinden, Jouke, Verwulgen, Stijn, Watts, Regan
Format: Article
Language:English
Subjects:
Agile development
COVID-19
Nimble manufacturing
Product development
Rapid prototyping
Respirator
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Summary:[Display omitted] •Design and deployment of a nimble manufacturing system of filtering facepiece respirators under pandemic conditions.•Additive manufacturing as a resilient manufacturing method.•Development of a 3D-printable exhalation valve model, validated with seven different 3D-printing materials.•Innovative adaption of HMI shown by the development of a novel cobot end-effector to perform ultrasonic welding.•Manufactured filtering facepiece respirators sent out for European pandemic certification for PPE. The SARS-CoV-2 pandemic presented European hospitals with chronic shortages of personal protective equipment (PPE) such as surgical masks and respirator masks. Demand outstripped the production capacity of certified European manufacturers of these devices. Hospitals perceived emergency local manufacturing of PPE as an approach to reduce dependence on foreign supply. The fact of a pandemic does not circumvent the hospital’s responsibility to provide appropriate protective equipment to their staff, so the emergency production needed to result in devices that were certified by testing agencies. This paper is a case study of the emergency manufacturing of respirator masks during the first month of the first wave of SARS-CoV-2 pandemic and is separated into two distinct phases. Phase A describes the three-panel folding facepiece respirator design, material sourcing, performance testing, and an analysis of the folding facepiece respirator assembly process. Phase B describes the redevelopment of individual steps in the assembly process
ISSN:0278-6125
1878-6642
DOI:10.1016/j.jmsy.2021.03.016