Design Reality Creates a Better Respirator Using 3D Printing

In late 2012 we had the pleasure of visiting Design Reality, a highly sought-after design consultancy nestled in the picturesque hills of Denbighshire, North Wales.

Troy Baker tries out the new General Service Respirator – prototyped on the Objet260 Connex.

We were greeted by the company’s Managing Director Troy Baker and Technical Director Graham Wilson who kindly allowed us to film them at work and talk about some of the high profile projects they’re using the Objet260 Connex system to bring to life.

One that particularly stood out for us was a new military respirator designed to protect UK armed forces against chemical, biological and nuclear particles – unfortunately a very real threat facing troops in the field today.

Using the multi-material 3D printing system, Troy and Graham were able to accurately prototype every single aspect of the mask, from the rubber seals to the rigid clips and fasteners to the transparent visor. And if you know anything about Connex technology, you’ll immediately appreciate that these rubber/rigid parts were printed together as a single homogenous piece – thereby eliminating the work of separately printing and gluing the different material elements of the mask by hand!

And the end result? A respirator that delivers the best protection along with a design that’s more comfortable and easier to use than ever before.