PolyMask: Aerosolization-proof NIV masks

COVID-19 has undoubtedly caused a huge strain on our modern healthcare system by creating a huge shortage of ventilators. Luckily, the FDA has approved the use of modified non-invasive ventilation (NIV) for treating patients with mild COVID-19. Unfortunately, our current NIV technologies pose a huge risk towards front-line healthcare workers since they are prone to aerosolization of the virus.

PolyMask is a 2-part NIV mask consisting of an airtight ICU ventilation mask and a detectable filtration valve. Using PolyMask, we can filter out 99.97% of inhale and exhale particles from COVID-19 patients, allowing us to prevent aerosolization of the virus. This allows us to help thousands of COVID-19 patients by providing NIV treatment at a low cost. The design of PolyMask uses a very simple manufacturing process, allowing us to cost-effectively and cheaply provide PolyMask to hospitals and healthcare facilities.

COVID-19 is expected to last 12-18 months and has already caused a huge shortage in the technology required to provide the most effective COVID-19 treatment—ventilators and ventilation equipment. Estimates show that 10% of all COVID-19 patients require ventilation and only 20% of those “will ever come off” the ventilator. In addition, it's estimated that more than 880,000 ventilators will be needed to meet the demand. In comparison, only 77,000 ventilators were needed last year to meet the demand for the entire world. Ventilator manufacturers have boosted their production up to 50%, but to meet the demand, we need a 1,000% growth in production.

Due to the shortage, many hospitals and healthcare facilities have started to build make-shift masks in attempts to provide treatment to COVID-19 patients. Luckily, SARs studies have shown that non-invasive ventilation (NIV) can be used to treat mild COVID-19 patients and that there are more than a million NIV machines at disposal. Unfortunately, these technologies are prone to aerosolization and can increase the spread of COVID-19. While the FDA acknowledges this and has approved several modifications to CPAP and BiPAP NIV technologies, they are not effective and still pose a risk to front-line healthcare workers.

PolyMask is a foldable and aerosolization-proof ventilation mask that can be used to provide non-invasive ventilation (NIV) to mild COVID-19 patients. PolyMask consists of detectable 2 parts: a foldable mask and a filtration valve. The foldable mask that can serve as a normal standalone ICU ventilation (BiPAP/CPAP) mask. Since it is foldable, the manufacturing process will be easier and cheaper (compared to normal BiPAP/CPAP masks). We plan to manufacture it with polycarbonate and clear vinyl, allowing it to be disinfected with UV lighting. The filtration valve will only be used in cases where the illness/virus can be aerosolized. It will easily connect to the base mask and filter 99.97% of inhale/exhale particles using melt-blown nonwoven fabric.

The PolyMask will primarily help hospital workers and COVID-19 patients. Using its aerosolization-proof design, the PolyMask can prevent the spread of COVID-19 inside hospitals, protecting healthcare workers. The shape of the mask is designed to perfectly shape a patient's face, minimizing air leakage and potential spread of the virus. Overall, this can reduce the number of COVID-19 cases. 

The PolyMask perfectly aligns with the area of the challenge that aims to create a cost-effective solution that can slow the spread of viruses (COVID-19) and protect healthcare workers. Polymask is aerosolization-proof and can prevent the spread of the virus. Since it is cost-effective, it can protect many healthcare workers at a low cost as well as provide curial NIV treatment to COVID-19 patients at the same time. Overall, this will help patients recover and slow the spread of COVID-19.

PolyMask was designed and engineered specifically for the COVID-19 pandemic. We focused on providing maximum effectiveness for NIV treatments, whereas our competitors focused on the comfort of the user. This allowed us to create a ventilation mask that is airtight. While PolyMask is less visually appealing and has less consumer features, it is the only mask that can fundamentally prevent aerosolization.

PolyMask was designed to be a multipurpose mask. It can be used by EMS, in the ICU, and for CPR. It’s folding mechanism also allows it to be stored anywhere. We use a simple manufacturing process and common materials. This allows us to manufacture in bulk at an estimated price of $20 USD per mask. Shipping and other fees are estimated to be $5 USD per mask. In addition, PolyMask will be manufactured with clear vinyl and UV resistant polycarbonate to allow for quick and safe disinfection using only UV light.

The core technology that powers the PolyMask are its foldable mechanisms and aerosolization-proof design. It's designed specifically so that no air escapes from the mask, maximizing safety for both the patient and the doctors and workers in the room. The PolyMask achieves this with a filtration valve that is attached in-line with the tubes and an airtight silicone lining on the sides of the mask which contacts the skin. This ensures that the virus won't spread from either the internals of the mask or the oxygen tubes connected to it.

In the future, we plan to implement IoT and AI into the mask. We will be using microsensors that are connected to a wireless communication device to monitor the patient. The data from the communication device will be sent to a computer, which will use AI to perform health analyses on the doctor's behalf. It can also be connected to the ventilator to automatically adjust air pressure and humidity.

PolyMask uses manufacturing and origami-engineering technologies. PolyMask will be manufactured using technologies such as CNC and injection molding. Its design was inspired by origami engineering, which for complex shapes to be folded/flattened. Origami engineering is current being used for solar panels on space probes and in the roof of convertible cars.

We currently are not serving anyone as our project is just a prototype. However, we expect it to grow very quickly. We aim to finish our MVP by July 31st and ship about 20 masks a week in the first month and up to 100 a week by next May. In total, we would have served around 1200-1500 masks in 1 year.

In the second year, we expect to see a drop in sales as the COVID-19 pandemic wears off. We aim to sell only 1000 masks that year. However, as we continue to develop our mask and aim to replace traditional noninvasive ventilation masks with them, we expect to ship more masks in the following years. By then end of 5 years, we plan to have already shipped at least 25,000 masks.

Within the next year, we aim to ship our first thousand masks and develop a more efficient, airtight design for reducing the escape of air from the mask. In the year after that, we will implement IoT and sensors inside the mask to track the patient's respiration rate and pressure. Around 2-3 years into the future, we will develop a machine learning algorithm that will analyze the data received from the sensors and optimize pressure for treating the patient.

Since PolyMask can also be used for CPR, we also aim to work with first-aid kit companies and form a B2B relationship to get our masks into consumer and EMS first-aid kits. After that, we will find ways to streamline our manufacturing process and reduce costs while refining the design and technology of the mask.

Currently, one of our largest barriers is the lack of financial and raw resources/materials. We don't have the materials nor money to build and injection mold (required for an MVP). Medical grade equipment and materials are especially difficult to find especially in this time. Injection molding is very costly and we don't have the financial resources to order a mold.

Another barrier is the total technical expertise in the team. While companies may employ dozens of experienced, skilled, and knowledgeable scientists to focus on a singular problem, we do not have this kind of knowledge. Research can only take us so far and we've reaching out to health professionals in order to design a mask to best suit a hospital environment. Unfortunately, given this situation, they were all extremely busy and many could not find the time to talk to us.

We have been using our network and cold-emailing medical professionals to provide feedback on PolyMask. We have also been competing in competitions and pitching PolyMask to raise money to purchase supplies and prototype our mask. Most recently, we have applied to a few startup incubators in hopes for mentorship and additional funding for PolyMask. We also have a mentor to help us file a patent and navigate through the legal obstacles. 

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Ryan is an incoming freshman at the University of Waterloo and is the lead of PolyMask. He has built multiple side-hustles, competed in various business competitions, consulted for multiple companies, built pitch decks and written business plans. He can code and have worked with many engineering aspects of the project. Marcus is a rising high school senior and is skilled in market research, external affairs, testing/feedback, and is the face of the project. During the early stages of PolyMask, he was in charge of the regulations and legal aspects of the project. Vedaant is also a rising high school senior and the head engineer. He has multiple years of involvement in robotics, CADing, CNC, prototyping, UI/UX design, and other hardware aspects of PolyMask. He currently does the designing and CADing of PolyMask.

Due to the demand in ventilators (and ventilator alternatives), we plan to sell directly to hospitals and healthcare facilities (government contracts) in the near-term. After the COVID-19 pandemic, we hope to continue selling to hospitals, but will also diversify to other geographic areas (outside North America and hopefully third-world countries). We will also aim to work as a B2B merchant with first-aid kit companies to get PolyMask into consumer and EMS first-aid kits.

So far, PolyMask has only relied on grants and prize money (from competitions) to find itself. Lately, we have also been accepted to an incubator and currently plan to join it for summer 2020. The incubator will help fund PolyMask's development and provide much-needed mentorship. When PolyMask launches, we hope to gain financial sustainability by selling it to hospitals and healthcare facilities. Since the demand will decrease when COVID-19 is over, we plan to create a second revenue stream by partnering with first-aid kit companies and getting PolyMask into first-aid kits.