Redesign of N95 Respirator

August, 2022


This project aims to propose a design of N95 Respirator to improve the comfort and adjustability of current respirators and accommodate as many ANSUR II population as possible. The design parameters are mask width, mask breadth, top headband length and adjustability, and bottom headband length and adjustability.

An experiment was conducted to measure related anthropometric variables and subjective ratings of participants.

My role

Conducted the whole project with other team members

Design parameters

  • Mask width​

  • Mask breadth​

  • Top headband length & adjustability​

  • Bottom headband length & adjustability


Within-subject experiment:

Participants (8 females, 10 males)

  • Step 1.  Measure 4 anthropometric variables

  • Step 2.  Ask participants to wear 3 masks and measure  their preferred headband length

  • Step 3.  Each participant performs three tasks wearing each mask: normal breathing, deep breathing, turning head

  • Step 4.  Each participant completes a questionnaire  asking comfort level of each mask 

Statistical analysis

Headband length (& adjustability):

Fit regression models of:

  • Top headband length <-- Head circumference + BMI

  • Bottom headband length <-- Neck circumference + BMI

Mask shell dimensions:

  • Fit a regression model of the subject's comfort score to determine the significantly influential factors of comfort

  • Calculate the sensitivity of each individual based on comfort scores

  • Use bivariate accommodation to design masks with 3 different sizes


Designed the different top band and bottom band for male and female separately based on linear regression models

Designed three different sizes for mask's width and length (unisex design)