Off-Ear Mask Headpiece (Adjustable)

Project

A lightweight and low-profile headpiece to alleviate ear stress from mask straps. Two version included; one for surgical masks (style 'A') and one for cloth masks (style 'B'). Prints in two pieces (left and right), assembled with a lock and key mechanism that allows for three size settings. The top and bottom lock can be adjusted separately to fit different head shapes. 

Style 'A' has six hole placements to adjust the vertical position of the straps above and below the ear. Style 'B' has four larger hooks that protrude forward to accommodate shorter cloth straps.

Printing

The thickness of the headpiece is 1.20 mm to keep it thin enough to be flexible but strong enough to not break. The locking mechanism extends the overall height to 3.20 mm. 

The left and right parts of the headpiece will fit on a standard print bed. When positioning, align both locks close to each other so the print head does not have to travel far for the last two millimetres.

The locking mechanism works by having four small overhangs that the 'key' slides under. Separate 'lock' and 'key' STL files are included for testing.

I recommend only using supports if they can be completely removed; any leftover supports might get in the way of the locking action. Likewise any drooping in the overhang areas will also get in the way. 

Print Time (Approximate)

Style 'A' (0.4 mm Nozzle, 0.20 mm layer height): 52 minutes.

Style 'A' (0.6 mm Nozzle, 0.20 mm layer height): 37 minutes.

Style 'B' (0.4 mm Nozzle, 0.20 mm layer height): 60 minutes.

Style 'B' (0.6 mm Nozzle, 0.20 mm layer height): 45 minutes.

Settings

Printer: Prusa MK3S

Material: AMZ3D Black PETG

Temp (Nozzle): 230

Temp (Bed): 85

Nozzle: 0.6 mm 

Layer height: 0.20 mm

Supports: No

Fill Density: 100%

Bridge Fan Speed: 100%

No special modifications to the settings were made with the exception of increasing the bridging fan speed from 50% to 100%. Recommended layer height is 0.20 mm.

Recommended nozzle diameter is 0.4 mm or 0.6 mm as the thickness of the locking mechanism walls are 1.20 mm which both nozzles will divide evenly into.

Files

Off-Ear.Mask.Headpiece.Style.A.Left.stl

Off-Ear.Mask.Headpiece.Style.A.Right.stl

Off-Ear.Mask.Headpiece.Style.B.Left.stl

Off-Ear.Mask.Headpiece.Style.B.Right.stl

Off-Ear.Mask.Headpiece.Test.Lock.stl

Off-Ear.Mask.Headpiece.Test.Key.stl

Assembly

1. Place the left and right parts on a flat surface with the arrow indicators pointing away from you, lining up the bottom lock and key. 

2. Overlay the key into the lock and press down until it fits in place. 

3. Grab the both parts and pull them away from each other. The key will slide under the overhangs of the lock securing them together.

4. Bend the headpiece and combine the top lock and key as before.

Wearing

Thread the mask straps through the holes, noting the directions of the arrows. When wearing, the arrow indicators should point to the top of your head. Place on top of head and pull down mask into place.

If the headpiece is slipping backwards, tighten by holding the headpiece with one hand and pulling down the mask straps behind both ears.

Style 'A' headpiece is preferred when wearing a hairnet, as the hooks in style 'B' headpiece can get caught in the netting. Any PPE helmet or visor that has plastic head-straps might cause discomfort when worn over top either style headpiece.

Durability

Style 'A' has yet to break under normal use. The style 'B' hooks might snap off if the cloth mask straps are too short and you try to pull the mask down over your face. A work around for this is unlock the bottom strap, position the mask and headpiece on your head, and then lock the bottom strap.

Warning / Disclaimer

If you experience discomfort or pain while wearing, stop using immediately. Not guaranteed to work with all head sizes and shapes. Use at your own risk.