New Generation of Masks

The challenge faced in the US and globally today is the shortage of both meltblown fabrics (the most critical component of the mask) and the converting capacity.

In response, NWI has developed meltblown filter media for both surgical masks and N95 and N99 masks and is working with partners who are converting these into masks.   This, however, is not sufficient.

One question that comes up is: How About Reusable Masks?

This is an interesting question and CDC has solicited proposals in the last decade or so targeted at reusable masks or masks that can be re-sterilized.

The challenge is how to recharge the mask after laundry or sterilization… And, what structures can be used to form a structure that can be decontaminated and reused without losing performance or damaging the filtration medium?

The Nonwovens Institute has spent a lot of effort in developing high-efficiency spunbond filter media.  The material is a structure that is bonded by hydroentangling and can offer pressure drops in the range of what you find for most facemasks (15 to 45 Pascals).  The efficiency is in the range of 80 to 85% for a single layer, and is durable, and can be reused if decontaminated by appropriate methods.

Sample Condition Efficiency (%)

0.3 Microns

Efficiency (%)

0.1 Microns

Pressure Drop (Pa)
One layer – 125 g/m2 As Received 88.0 98.0 15.5
Two layers As Received 98.5 99.5 30.2
Three layers As Received 99.5 99.9 42.2

These structures in a properly designed mask design can reach N95 or higher levels of performance, while a single layer can easily be designed to pass the FDA surgical mask requirements. FDA just announced guidelines for non-regulated masks.

We believe that in this time of crisis, a properly-designed reusable mask may be worthwhile to consider and while it may not reach the performance levels of the N95, they still provide a significant level of protection to the public; see recent publication on the topic of re-use.

The Durability of Disposable N95 Mask Material When Exposed to Improvised Ozone Gas Disinfection

What if the current crisis continues into the next year?  The strategies would include the following short term and longer-term options.  And, it is important to allow new structures that may not have the FDA or NIOSH approval in hand.  This is not to say that we should compromise quality but allow the use of non-certified masks that meet the pressure drop and efficiency requirements of the certified masks documented by a 3rd party certified lab.  FDA recently published guidelines that must be strictly followed.

The Nonwovens Institute stands ready to help with the current crisis and will be happy to engage in a dialog.  NWI has redirected ALL of its efforts to forming filter media for the current crisis.