A critical component of a successful N95 respirator alternative product in the United States is the ability to circumvent traditional avenues of sourcing and manufacturing. The purpose of this research was to develop and test an alternative facemask design to combat shortages of N95 facemasks by creating a design that can be produced locally with low specialization of materials and process. Through an interdisciplinary network of experts, a new mask design was developed and tested that uses repurposed air filtration media and commercially available components. Manufacturing viability was tested using a small unskilled workforce (n=10-20) to create 6000 masks over 10 days. The ability to quickly produce masks at scale using an unskilled workforce demonstrates the feasibility of the mask design and manufacturing approach to address shortages of critical healthcare equipment, mitigate risk for healthcare and essential workers, and minimize the transmission and spread of disease.

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