Received: 31 August 2020 | Revised: 24 May 2021 | Accepted: 6 August 2021

DOI: 10.1002/hfm.20934

A study on usability and design parameters in face mask:

Concept design of UVW face mask for COVID‐19 protection

Bahram Ipaki1 | Zahra Merrikhpour2 | Mohammad S. Taheri Rizi3 |

4
Saman Torkashvand

1
Faculty of Design, Tabriz Islamic Art
University, Tabriz, Iran Abstract
2
Industrial Design Department, Art and The aim of this study is to investigate the usability of conventional masks to prevent
Architecture Faculty, Bu‐Ali Sina University,
Hamadan, Iran
the transmission of coronavirus 2019 (COVID‐19) and subsequently design the
3
Department of Industrial Design, University proposed concept of the mask to reduce leakage and increase efficiency. Acute
of Tehran, Tehran, Iran respiratory syndrome COVID‐19 is spreading around the world and can be trans-
4
School of Medicine, Hamadan University of mitted from one person with COVID‐19 to another through personal contact and
Medical Sciences, Hamadan, Iran
breathing. Improper design of current masks can lead to virus transmission. One
Correspondence hundred fifteen users participated in the study using a simple random sampling
Bahram Ipaki, Faculty of Design, Tabriz Islamic
method in which N95–FFP2 face mask and surgery face mask usability tests were
Art University, 37CV+FW8 Nowbar, Tabriz
51376‐53515, East Azerbaijan Province, Iran. chosen as the most widely used face masks in Iranian people with an online usability
Email: [email protected]
questionnaire. Data were analyzed by SPSS. The results showed that the usability of
the N95–FFP2 face mask with a total average of 4.46 and a surgical mask with a
total average of 3.35 cannot be considered acceptable. Anthropometric and formal
changes in people's faces and improper design of the face masks used make it
necessary to review the mask redesign measures to increase the prevention of
pathogens. In this study, new parameters for face mask design are proposed. Thirty
different types of jaws have been considered with the help of CorelDRAW software,
along with ideas for optimal mask design with UVW mask concept to be accessed by
manufacturers around the world.

KEYWORDS
adaptability, design parameters, face anthropometry, personal protective equipment, usability
testing and evaluation

1 | INTRODUCTION coronavirus up to a radius of 2.5 m when a mask is not used. If people

gather, the rate of spread of infectious diseases will increase. Breathing is
The disease of coronavirus 2019 (COVID‐19) is caused by acute re- one of the most common ways of transmitting coronavirus disease. Since
spiratory syndrome first seen in 2019 in Wuhan, China (Ren et al., 2020). hospitals also have limited capacity to admit patients, the best approach
COVID‐19 is an acute respiratory virus that is similar to MERS‐CoV in to prevent the spread of COVID‐19, research has shown, is to avoid
that it causes high persistence in the air at low temperatures (Bernard admitting patients contracted with other routine respiratory viruses such
Stoecklin et al., 2020; Pyankov et al., 2018). The COVID‐19 is a relatively as influenza to hospitals (Centor & Fisman, 2020; Dai et al., 2020;
greasy virus that can stay in the air for up to 3 h and remains on smooth Klompas, 2020).
or polished surfaces compared to textured surfaces. Also, if a coronavirus‐ Researchers have long suggested that masks should be used to
contracted person is breathing in one place, he can spread the prevent respiratory infections, such as the flu, to limit the release of

664 | © 2021 Wiley Periodicals LLC wileyonlinelibrary.com/journal/hfm Hum. Factors Man. 2021;31:664–678.
IPAKI ET AL. | 665

viral droplets. To combat coronavirus, the importance of mask pro- the design of the new N95 mask, the results of which showed that
duction has been highlighted (Leung et al., 2020). It is recommended the filter of that mask is very effective in preventing the entry of
to use N95–FFP2 and N95–FFP3 face masks to prevent, control, and influenza viruses (Zhou et al., 2018). While for air conditioning, they
manage the COVID‐19 (Cascella et al., 2020). We consider a mask as used a smart fan for inhaling and exhaling, so possibly the production
important medical equipment in strengthening this approach and process is longer and the final manufacturing costs are higher. Also, in
reducing the problems caused by it. The World Health Organization the 2016 study by Zhang et al., the presence of a fan was shown to
stresses the use and production of masks to deal with COVID‐19 and be useful for reducing the accumulated concentration of carbon di-
also on their usability, correct use, and efficiency to reduce the risk of oxide and temperature control (Zhang et al., 2016). But the inter-
transmission and prevent the creation of a false sense of security. esting point is that technically, the entry and exit of air requires a
Because the face mask can limit some face‐to‐face contact that rotating fan on both sides, which makes it difficult to breathe or
usually includes coughing, abnormal breathing, and droplets con- exhale due to the presence of a fan with a propeller on one side. In
taining microorganisms, which is one of the major sources of virus this way, if the fan makes it easy to exhale, air will pass around the
spread (World Health Organization, 2020). Designing is one of the mask in the inhaling mode. So again, we have a problem with us-
most common ways to improve healthcare needs. Choosing a design ability. In the case of the N95 mask without filters and the surgery
approach based on design position can determine the ultimate quality mask, the research conducted by Tang et al. (2009) showed that a lot
of a product design or medical service. Human factors are one of the of air passes through the face masks and never does filtering involve
main disciplines in design for health (Branaghan et al., 2020). The a large part of the air (Tang et al., 2009).
patient‐oriented design focuses on preventing or controlling a dis- The study by Radonovich et al. (2019) also did not show a sig-
ease known to be of great importance in work‐oriented approaches nificant difference in comparing the effectiveness of the N95 mask
(Reis et al., 2011). The usability test is a one‐step design experiment with the surgical mask in preventing the risk of catching the flu
in which designers technically evaluate the background of a product (Radonovich et al., 2019). While there are various models of N95
to grasp a better design (Geisen & Romano Bergstrom, 2017; Rosson masks. In this way, it can be admitted that the N95 masks can not be
& Carroll, 2002). In these usability tests, a user is tested in interaction more effective or efficient than surgical masks. Because surgical
with a product to determine the efficiency of the product (Lee & masks have a simpler structure and are more easily and quickly
Ha, 2019). This is done with the aim of discovering gaps and product produced, thus being also cheaper. However, according to other re-
problems that are an inseparable part of user‐centered design. search, these face masks have inferior usability.
However, in the patient‐centered design approach, all activities move In a 2020 study by Suen et al., cup and flat‐fold platforms of N95
to prevent the development of the disease in a normal user and masks (Figure 1) were compared with each other in terms of usability,
prevent the recurrence of the disease (Reis et al., 2011). with the information from 104 nursing students. Cup and flat‐fold are
two platforms of current face masks by duck and circular form design
used in different countries. The results showed these masks are not
1.1 | Research background suitable for continuous protection because of leakage and entry of
the unexpected amount of air and it is necessary to increase the
One of the main symptoms of the COVID‐19 is shortness of breath observance and ensure the respiratory protection of the users in the
(Patel et al., 2020). Therefore, people infected with COVID‐19, as a redesign and development of the design (Suen et al., 2020). In a 2015
personal duty to maintain the health of their family, the public, and study by Cho et al., the rate of air passage during respiration was
public health, in addition to controlling the outflow of the virus from observed when moving the head in three different models of 3M‐
their lungs to the outside environment, should be able to breathe N95 face masks used in best form a performance was 46% during
easily, demanding that the design of masks plays a special and helpful exhale (Cho et al., 2015). Also, in 2010, Bowen's research on mask
role. It has been reported that the effectiveness of all personal pro- resistance to the swine flu virus (H1N1), severe respiratory distress
tective equipment for the healthcare staff of COVID‐19‐infected syndrome (SARS), and pathogenic avian influenza (HPAI) emphasized
patients is low (Ng et al., 2020). Some personal protective equipment the protection of surgical masks and unfiltered masks than
in healthcare comprises masks, gloves, shoes, safety clothing, gog- N95–FFP3 was much lower (Bowen, 2010). O'Kelly et al. (2021) also
gles, and hats. It can be concluded that the optimal design of care reported low accuracy in fit‐testing of KN95, N95, surgical, and cloth
equipment is of great importance and will be effective in preventing face masks, and considered redesign based on facial proportions
the transmission of this virus. COVID‐19 is also very dangerous for necessary for better protection (O'Kelly et al., 2021).
the elderly (Applegate & Ouslander, 2020). In this way, considering
that the shape of the jaw and face of this group of people is quite
different from the youths, the design of the mask becomes more 1.2 | Objective problems
challenging. A study by Chughtai et al. (2020) highlights that there are
differences in countries' health policies for using FFP2 and FFP3 In general, in the anatomy of the head and face, mainly female and
masks to prevent COVID‐19 (Chughtai et al., 2020). Yet, it is not clear child users have more delicate jaws. However, we see the lack of this
what this mask does for the COVID‐19. Zhou et al. (2018) worked on type of mask in the design of existing examples, and many of the
666 | IPAKI ET AL.

FIGURE 1 Left to right: N95‐Cup 3M, N95‐Flat Fold 3M, and N95‐Flat Fold Nanofiber

most commonly used masks are designed in one size, posing a serious terms of age and gender differences was the problem of interaction with
problem, which is to adapt the design of the mask to the anthro- different users and also the impossibility of direct access to them due to
pometry of different jaws. To do this, we must first know what is the coronavirus disease. Since in the selected topic, the focus is on the design
status of common and widely used masks. of the product itself rather than the physiological issues, the inequality of
the number of male and female participants in this study is low, and on
the contrary, the users were selected randomly. Also, their age difference
1.3 | The purpose statements and segregation are descriptive only due to the dispersion and similarity
of the participants and have no effect on the results. Details of partici-
The effects, complications, and mortality of COVID‐19 and other pants' data are shown in Table 1.
epidemics are spreading, and designers need to work with doctors,
nurses, and other researchers in this area and make the best of their
ability to inhibit or control the virus. If a mask is used to ensure its 3.2 | Data collection
effectiveness and prevent the risk of transmitting the virus, the de-
signed mask should be very effective in empowering the users to A questionnaire was created in Google Docs and then the questionnaire
have more ability to prevent pandemics. This study, by examining the link was sent to the participants on WhatsApp, Telegram, Instagram, and
usability of N95 and surgical face masks, seeks to suggest an optimal also emails. Before answering the questionnaire, participants were re-
design of the mask to prevent the spread of respiratory viruses with a assured that their information will remain confidential and that they were
focus on preventing the spread of COVID‐19. N95 and surgical face free to answer questions, that these permissions were approved by them.
masks are widely used and have not been evaluated yet by some Also, with this method, users in different cities of Iran could answer the
usability criteria in recent studies. Assessment in this study can lead usability questions. The importance of the issue is that in usability
to recognize the problems and provide design solutions to them. questions, even if at least three users are dissatisfied with the perfor-
mance of a product, it means that the product has a problem in terms of
usability. Because this is the user's need. In this study, the utility of the
2 | PROCEEDINGS N95–FFP2 face mask and the surgical face mask shown in Figure 2 were
investigated. These samples are the most common types of masks used in
This is a dual process study that includes quantitative and qualitative
cases in such a way that the links created between qualitative and
quantitative issues lead to the output of the conceptual face mask
TABLE 1 Demographic information of participants
design. To evaluate the existing masks, the usability test will be used
Demographic Frequency Valid percentage
to identify the existing gaps and move toward the proposed design to
categories Case 1 Case 2 Case 1 Case 2 Difference
solve those problems.
Gender

Male 25 35 21/7 30/4 −10

3 | S TU D Y 1 : ME T HOD S Female 15 40 13 34/9 −15

Age
3.1 | Participants
+18 41 74 35/6 64/4 −33

Participants in this study included 115 Iranian men and women who were Sensitivity 11 12 27/4 16
chosen by convenience sampling through an invitation on social media. Note: Case 1 represents N95–FFP2 masks and Case 2 represents surgical
One of the reasons for the inability to determine the target group in masks.
IPAKI ET AL. | 667

Iran among the general public, which can be easily prepared and have TABLE 2 Usability testing questionnaire
been widely used in the corona pandemic. In Iran, every user uses these
Q1. I feel comfortable while using this mask
masks at least several times. High cost is one of the main reasons for not
Q2. Using the mask, I do not have any concern of contaminated air
trying other standard masks. The image of both masks was placed in an
entering in
online questionnaire so that each user could choose an option, and they
were also asked to select the sample they most used. Q3. Mask is fitted well on the face, nose, chin, and jaw

Q4. The air does not pass the mask edges while inhaling and exhaling

Q5. While speaking I am sure the mask is on the right position

3.3 | Usability questionnaire
Q6. Rotating left and right, I am sure the mask is fitted properly

The usability test of face masks can show us what features of design Q7. Moving head up and down, I am sure the mask is fitted properly

create problems for users. In this study, we designed eight usability Q8. While wearing mask, I feel safe against virus penetration
questions with a Likert scale based on five independent variables. The
Likert scale comprised scores: Inefficient, 1; Very Poor, 2; Poor, 3;
Average, 4; Acceptable, 5; Very Good, 6; and Excellent, 7, which are Approval and standardization of the questionnaire will also be im-
defined according to users' feedback and then their effective average portant. For this reason, the face validity and reliability of the ques-
is announced. Table 2 shows the designed questions, and Table 3 tionnaire were first checked by six faculty members in the fields of
describes the research variables. Table 2 shows the relationship be- two ergonomists, two industrial designers, and two physicians. Then,
tween the questions and the variables as each of the variables is after collecting the data using Cronbach's alpha, their internal con-
described. Some variables are adjusted to the research of Radonovich sistency and reliability were quantified and the final confirmation was
et al. (2019) and Suen et al. (2020), and others are determined by reached, as mentioned in Table 4. According to the results of Cron-
reviewing the research background. Radonovich et al. (2019) stated bach's alpha (α > .7), the questionnaire can be repeated by other re-
that there is no difference between N95 and medical masks in terms searchers. This result shows that the designed questionnaire has
of safety from the influenza virus family. This problem showed us standard capabilities. After filtering the data, the pure and outdated
that there are low‐safety and low‐fitted features in N95 and medical data were analyzed by SPSS 19 and then their details, such as middle,
face masks. Also, the study of Suen et al. (2020) has confirmed the mean, low limit, and high limit were determined by box and whisker
Radonovich et al. (2019) studies about fit testing and effectless of plots. While in standard usability, according to the Likert scale, the
that to high‐safety for breathing systems (Radonovich et al., 2019; acceptable level is at 5, the level at 6 and 7 shows very good and
Suen et al., 2020). excellent usability.

3.4 | Data processing 4 | STU DY 1 : F I NDI NGS

Due to the fact that not all parameters are well‐supported in the Due to the feature of N95–FFP2 mask in the usability announced 38
latest study questionnaires on mask usability, the design of a devel- users, there is the main design problem is in the areas of safety with
oped and standardized questionnaire becomes very important. the median of 4.5 and average of 3.93, fit‐testing with a median of

FIGURE 2 Left: Case 1 (filtered mask N95–FFP2); right: Case 2 (surgery mask)
668 | IPAKI ET AL.

TABLE 3 Relation between variables and questions

Independent variables Description Variables in questions

Comfort Convenience between using the mask and adapting to different parts of the head Q1 + Q3

Breathing Air leakage due to noncompliance with facial anthropometry and easy breathing while using Q2 + Q4
the mask

Fit test Comfortable placement of mask components on the head and face as well as no air leakage around Q2 + Q3 + Q4
the mask

Unmovable Do not move the mask over the head and face when talking left, right, up, and down Q5 + Q6 + Q7

Safety Feeling safe and not worrying about the entry and exit of polluted and nonpolluted air after Q2 + Q8
wearing the mask

TABLE 4 Cronbach's alpha of research‐made questionnaire from results of usability at 3.35 show the average usability and in this
this study regard, it needs to be redesigned. The immovability in the surgical
Items Cronbach's α Std. α G6(smc) Average R mask with a median of 4.33 and an average of 4.18 does not seem to
All variables .8511 .8478 0.8693 .4106 be a major design problem as in the case of the N95–FFP2 mask and
the previous design features can be used to fix the mask on the face
Q1 excluded .8291 .8254 0.8492 .4031
in new models. But anthropometric changes create new require-
Q2 excluded .8211 .817 0.841 .3895
ments. According to the results of the review of parameters and
Q3 excluded .8218 .8185 0.8415 .3918 capabilities, re‐designing the mask is essential.
Q4 excluded .8106 .8073 0.8321 .3744

Q5 excluded .8259 .8207 0.8288 .3954

5 | STUDY 2: METHODS
Q6 excluded .8281 .8228 0.8293 .3987

Q7 excluded .8316 .8278 0.8522 .4071 This part of the study shows an operating anthropometric design

Q8 excluded .8853 .8853 0.894 .5245 process, for which the design must support various anthropometric
data. The anthropometric‐based design provides good adaptability in
wearable equipment (Ipaki, Amirkhizi, & Heidari, in press). Therefore,
the modular design approach has been chosen to improve the flex-
4.83 and an average of 4.44, and comfort with a median of 4.0 and an ibility in the adaptation by face form so we can cover a variety of face
average of 4.06. While in the fit‐test variables and the safety, the shapes with different dimensions with configurability and different
skewness is toward the lower usability. There are fewer breathing sizes of the mask. The arrangement of the components in the mod-
problems with a median of 5 and an average of 4.53 and skewness ular design increases adaptability (Meyer & Lehnerd, 1997).
stretching below 5. However, the median and the average in the
immovability variable at 5.31 show that acceptable usability. In the
field of safety, due to the importance of the user's concern induced 5.1 | Engineering USP
by the entry of air around the mask and the subsequent feeling of
unsafe against the COVID‐19 and its prevention, in this study, this According to the usability results, the most important problem was
issue was considered as the most important design parameter. the inappropriate form and incompatibility of the design pattern of
However, the usability of the N95–FFP2 mask with a median of the masks with the anthropometry of different faces and in none of
4.7 and an average of 4.46 is between medium level and acceptable the situations, we saw results in a very good and excellent range. The
level. Therefore, only the design parameter related to immovability in results showed that changing the pattern design is necessary for
the N95–FFP2 mask is acceptable and can be implemented on similar greater compatibility. The ease of inhaling and exhaling was also a
products in future designs. Figures 3 and 4 show the independent serious problem so that to solve this problem, an air inlet filter and an
variables and the usability test results of the surgery face mask ex- air outlet filter should be considered.
pressed by 77 users and N95–FFP2 face mask by 38 users. According to a 2015 study by Cho et al., the N95 masks cause
In contrast, the surgical mask is not a good option. The main respiratory problems at 46% which, reviewing minor changes to improve
design problems are safety variables with a median of 2.5 and an filtering, is the same as the results of the current study. The usability for
average of 2.57, breathing condition with a median of 2.5 and an the breathing variable in the N95–FFP2 model is also associated with
average of 2.97, fit test with a median of 3 and average 3.23, comfort deficiencies. So that air conditioning is difficult to do through the filter
with a median of 3.5, and an average of 3.78, which show minimum (Cho et al., 2015). For respiratory protection, Suen et al. (2020) also
usability against coronavirus infection for 75 participants. Also, the emphasized the redesign of three types of N95 masks to increase
IPAKI ET AL. | 669

FIGURE 3 The box and whisker diagram and the test results of the applicability of the N95–FFP2 mask

FIGURE 4 The box and whisker diagram and the test results of the applicability of the surgical mask

respiratory safety and eliminate leaks (Suen et al., 2020). Due to the fact When using a face mask, the safety of fitting, convenience, and the
that inhaling is more difficult than exhaling, if the user does not need ability of verbal communication with others depends on the design fea-
mechanical ventilation, it is appropriate to have a one‐way filter. Yet, tures (Kirillov et al., 2013). Representing the measurement of the effi-
increasing the number of filters from one to two will increase the pos- ciency of the mask shows the importance of controlling air penetration
sibility of increasing the amount of oxygen in inhaling. from the distance between the face and the mask in the design. Ac-
Also, during the COVID‐19 pandemic, one of the main problems of cording to various experiments on masks, due to the presence of different
face mask use, that is the potential for pollution in the environment and anthropometric features in the people's jaws, is observable the leakage
disposable face masks (single‐use) are a new environmental challenge that around the mask and jaw, as well as around the nose and mouth. The
is playing a key role in microplastic pollution (Fadare & Okoffo, 2020; manufacturers must produce masks based on the regulations applied by
Sangkham, 2020). Recently, the use of reusable masks is expanding be- the World Health Organization (NIOSH) (42 CFR 84.135): Masks should
cause of the expensive price of N95 face masks and the weak usability of be designed to fit the shapes and sizes of different types of faces in terms
surgical face masks in different geographical locations (Shruti et al., 2020). of anthropometries (Table 5) (Institute of Medicine et al., 2007). The
So, reusability and washability is another issue that highly depends on the design of the hat and face mask has led to the collection of extensive
material used to make the mask. anthropometric information related to the head and face. This
670 | IPAKI ET AL.

TABLE 5 Facial dimension measured in the NIOSH‐sponsored Anthrotech study

Facial dimension Definition

Bigonial breadth The straight‐line distance between right and left gonion on the corners of the jaw

Bitragion subnasale arc The surface distance between the left and right tragion at the bottom of the nose

Bitragion chin arc The surface distance between the left and right tragion across the anterior point of the chin

Head breadth The maximum horizontal breadth of the head above the level of the ears

Menton‐sellion length The distance in the midsagittal plane between the menton at the bottom of the chin and at the
deepest point of the nasal root depression

Nose breadth The straight‐line distance between the right and left on the sides of the nostrils

Chin The protruding point on the bottom edge of the chin, along the jaw line
IPAKI ET AL. | 671

F I G U R E 5 Left: the supposed schematic of formal variation of jaw. Right: general scale of golden points in face and jaw variety. Source:
designed by authors

F I G U R E 6 The initial sketch of the left side of the mask with the chin adjustment strap and the hook–loop system in the nose section, the
concept of the right sketch using two filters and the view facing the main idea. Source: design by authors

information will be appropriate to determine the location of the eye, nose, formal similarity of the COVID‐19 to influenza and the large size of the
chin, and mouth against protective masks (Pheasant, 1996). Because of human COVID‐19 at 98 µg/m compared to the c‐type influenza virus
the wide range of users, the mandibular morphology, including thickness, with dimensions 149 µg/m, the feature used in the influenza mask can be
width and height, large and small faces, and facial curvature should be described in the new design to be effective (Vlasak et al., 1988).
considered. Researchers have also found that estimating the average
anthropometric dimensions of face length and lip length is not easy
compared with other facial dimensions, such as intermediate distance, 5.2 | UVW face modeling
nasal area, and protrusion.
In the following, according to the findings of the research, to achieve In this section of the research, considering anthropometric differences, 30
the details of mask design, the design guidelines are formulated. Re- types of jaws have been supposed to avail, designed with the help of
garding the necessity of including a filter in the mask to prevent CorelDRAW software. To create a sketch of the jaw and face form, a
COVID‐19, it is vital to specify what the filter and design feature should general division of the jaw form was performed by default. This face form
be. According to research by Zhou et al. (2018), the filters used in division was done in three styles of front‐view and 10 styles of side‐view
N95–FFP3 mask have the ability to filter out the flu virus. Due to the according to the general principles of Walter Foster head and face
672 | IPAKI ET AL.

FIGURE 7 Paper prototype of mask concept UVW (medium fidelity). Source: authors' design

FIGURE 8 Different views and applied components of designed concept with software

F I G U R E 9 Using a hook–loop system to fit the jaw and a two‐way locking button to adjust the strap to increase fit. The replaceable filter can
be used to estimate the average continuous usability and to add the required number of additional filters in each package. Source: authors' design
IPAKI ET AL. | 673

F I G U R E 10 Computer rendering of the product with Key Shot software and the basic pattern of the UVW mask concept

drawing in which the way of dividing and arranging particular parts of the the other for exhalation, and then that the filters should be re-
face is made in accordance with the shape and elements from adults and placeable. Also, should be used of two‐color design for the back/
children faces (Foster, 1997). In this category, each of the front‐view front of the filter materials in that the user can change the filters by
shapes combined with the corresponding side‐view shapes created the attention to inhalation/exhalation. Filters must be for single‐use and
30 various models of jaws and face forms. This process has done by after using a mask, they should be immediately changed or disposed
observation in which another 10 states were multiplied by each of the of. Afterward, it is necessary to put a number of filters in the mask
UVW jaws, based on which were done the formal design and geometric package for replacement and subsequent use.
patterns of the proposed mask. Totally, we take into account 30 different
forms of faces summarized in Figure 5. It should be noted that these
sketched face platforms almost covering the face form of male and fe- 6.3 | Hook–loop system
male users and even children.
It is important to fit the mask on the face. The hook–loop system in
this design makes the features modular and flexible. Meantime, we
6 | S TU D Y 2 : FI N D IN G S create more fittings by adaptive design properties from the
hook–loop system. In this concept design, we used an adjustable
This section reports the result of conceptual design according to the hook–loop system for better adaptation to the user's face. This is
background, instructions, and findings of Study 1. This content de- something like a shoelace.
scribes the operational aspects of the design and each design fea-
tures seven criteria, which are as follows.
6.4 | Strap

6.1 | Anthropometry and fitting The finding showed that the immovability variable of the studied
masks has problems and it is 2° away from the excellent state. It is
Due to the huge and diverse range of users, in general, available face often difficult to close and hold the mask on the face for a long time.
masks (surgical and FFP2–N95) have single‐size. It is important to Using a suitable strap for the mask can increase its continued use.
note that to increase performance and anthropometry, this design Here, we designed a two‐way locking button to adjust the strap to
must be produced under NIOSH anthropometric data and in four increase the stability and fitting of the mask on the user's face.
sizes: XL, L, M, and S. This design has its fundamental differences in
terms of more attention to the face anthropometry than other cur-
rent face masks. 6.5 | Adjustable design

Equitable use and flexible usage are very important principles in

6.2 | Filtering universal design. Adjustable design can make these two principles
possible to a large extent (Null, 2013). Operational use of this design
Air filtering in face masks is the most common vital issue of healthy method can support more users for face masks. Users can have more
respirators for the human body. Findings show us that the mask filter adaptation in terms of face form and face anthropometry in using the
must behave as being two numbers. One of them is for inhalation and face mask. In the design of the UVW face mask, the straps and pieces
674 | IPAKI ET AL.

TABLE 6 The advantages and disadvantages of the proposed design

Design criteria Situation Reasons

Face form Satisfaction Due to the three‐piece design with four different sizes

Breathing in Dissatisfaction Needs more research and depends on filter design

Breathing out Dissatisfaction Needs more research and depends on filter design

Fitting Satisfaction Due to the use of hook–loop system and strap for the chin

Unmovable Satisfaction Due to the setup on the face and using spring hook for strap

Fixing Satisfaction Using adjustable back‐strap

Safety Satisfaction Neglecting dangerous elements

Establishing speed Satisfaction The product is not complex

Using ability Satisfaction No specific skill to use, the ordinary user can use it easily

Filtering Dissatisfaction It needs more scrutiny but two filters must be used, one for inhalation and the other for exhalation

Changeable filter Satisfaction Filter concept is designed to be replaced

Continuous use Dissatisfaction Users may become tired of using the mask after a long time

Persistent use Satisfaction Washability and filter replacement may be applied until the loss of the main quality such as hook–loop
system

Facilitate Satisfaction Steps are easy to implement

Anthropometry Dissatisfaction Cultural and face frame are different and results can be generalized. Different sizes may help to overcome
the problem especially for the youth

Use of glass eye Satisfaction Using hook–loop system prevents the accumulation of breath vapor on glass

Special users Dissatisfaction Some certain people may not use this product and it is necessary to do more research

Cheap material Dissatisfaction Materials are cost‐effective

Permanency Satisfaction The materials used in the design are easily available in the market

Easy to tasks doing Satisfaction Product components are simple

Optimum production Satisfaction It is produced at the same speed as the N95 mask

Open–close Satisfaction It functions easily to open and close

Washable Satisfaction New filter can replace the old one after washing up to four times The hook–loop system is damaged

Learnability to use Satisfaction It is necessary to use the guideline and brochure

Anti‐allergy material Sacrifice This item was not investigated. Some people may be sensitive to…material

Easy assembly Satisfaction In this concept, sewing and thermal pressing are done easily in the factory

Structure simplicity Satisfaction The components used are known

Ease of manufacturing Satisfaction Due to the simple components, production is not complex

Packaging Dissatisfaction Packaging is important, the necessary information must be inserted and needs more research

Aesthetics Satisfaction Designing product is compatible with the color in medical equipment

on the nose and under the jaw provide the ability to adjust properly. washing and reusability. Because washability by cotton is low and
In this way, the user has more freedom of action in the proper use of linen material is in low resistance against the virus. But washability by
the mask. linen is high, and virus resistivity by cotton is high (Xiao et al., 2020).
Also, it has been reported that using cotton masks can be more ef-
fective in surgical masks if it is used in open environments to prevent
6.6 | Material the disease (Ho et al., 2020). So, maybe the composition of these
materials has the best performance. Some materials that are used for
We have limitations in this stage of face mask concept design. face mask production like nano‐fiber, carbonic, cotton‐silk, cotton‐
However, we suggest the linen‐cotton composite material for chiffon, cotton‐flannel (Chua et al., 2020) can be replaced with linen‐
IPAKI ET AL. | 675

cotton. Manufacturers must select usable materials for face masks can be used. Poor people may afford to buy three washable
according to the price and accessibility. quality masks over 20 disposable low‐quality masks. The location
and type of conditions for using the mask will also determine the
factors. The results of Liang et al. (2020) study showed that more
6.7 | Manufacturing evidence is still needed for the effectiveness of masks in a variety
of situations, including the method of use, the permissible limit of
Figure 6 is a selection of sketches from a collection of ideas that use, and the effects of use (Liang et al., 2020). The difference
show the generalities of the design in the early stages. Figure 7 between the present study and innovation from other research
shows a paper prototype made from an idea to show the ability to studies was the visual suggestion of the solution to overcome the
execute and extract a construction pattern. This physical model is problem instead of emphasizing the problem factors. This ap-
a medium‐fidelity prototype. Figure 8 shows images of the proach may speed up the process of solving problems. However,
computer‐aided concept. Figure 9 shows the performance system we also emphasized some problematic factors. On the contrary, it
and the key elements of the mask, which were prepared with the is very difficult to meet all the design needs in a study. Therefore,
help of Rhino software. Figure 10 shows the computer rendering more research is needed to complete the design work. However,
of the product from the front view, as well as the dominant our emphasis, according to past research and the results of this
pattern of the mask. study, is to focus on the new design of the mask, taking into
account the ease of production, along with increasing the health
efficiency and cost‐effectiveness of the final product.
7 | G E N E R A L D IS C U S S IO N

7.1 | Point of view 7.2 | Gaps and features

The present study was performed to usability testing of two surgical During the COVID‐19 pandemic, the face mask is a means of
and FFP2–N95 face masks, which are extensively used in Iran. The prevention. However, the use of improper masks maybe leads to
test usability output provided links to identify gaps and design needs false self‐confidence in some users because of the expense and
and also led to a purposeful review of mask design recommendations. scarcity of standard masks, poor supply chain management, and
As a result, it implemented design recommendations as a concept inefficiency of some governments in supplying the standard
design. The primary purpose of this study was to follow planning to masks, so that using nonstandard masks provides a kind of tem-
design the face mask with anthropometric support and face form of porary solution to commuting in public places and may not makes
different users and generalizable concept design so we could be any prevention or maybe have weak and limited performance in
exported more design information for a suitable respiratory protec- this regard, and contrary to popular belief they may be used as a
tive cover against Covid‐19. basis for increasing pathogens and transmitting the disease. Since
One of the reasons for users to employ the surgical mask public health aims to increase user access followed by making
more than the FFP2 mask was its cheapness and availability in the goods and services cheaper, instinctively, this will affect the
Iranian market. For this reason, we could not consider the number quality of the proposed mask, and to reduce the last price of the
of users to be equal. But the problem is that in the usability test, product, the structure of the design must be considered simple.
the average data is considered as the result. Although with the Meanwhile, due to the unknown nature of coronavirus and high
help of the usability test, it is possible to get an overview of the expansion power, and the possibility of engaging users with dif-
available products in a small range, given that the public lacks ferent age groups and different anthropometric characteristics, to
expertise in the field of product design and only examines it from control it, more advanced technology in the field of design, ma-
a practical point of view, this study cannot be considered for all terials, and manufacturing should be used. Naturally, this will lead
design parameters, and naturally, other methods must be used to to an increase in the final price. So, here, we come to the design
achieve them. The most important difference between this study paradox, which seems to need to be addressed, considering a set
and others is the more comprehensive study of mask design of rules. We checked a limited space. There are still a lot of op-
parameters as usability variables. The results of the current study portunities for designing an optimal face mask. Based on the re-
are consistent with those of Tang et al. (2009) and confirmed the sults of the theoretical phase of this study, we have proposed a
leakage of N95 and surgical face masks in that the quality and concept for a mask design, which can be standardized and pro-
usability affect the mask leading to the unwillingness of some duced worldwide. The idea was to implement the results of pre-
users to use the mask to prevent disease (Tang et al., 2009). vious studies and research on the product. We also included some
Unfortunately, these masks are not common and cannot be no- new design criteria that were not discussed in previous research
ticed in extensive use in different communities. If we assume that studies. Naturally, given the number of multiple parameters in a
the price of a surgical mask is half the price of a more optimized design and prioritizing them to satisfy the need, it cannot be
design mask, we must also consider the length of time the mask claimed that the design of a product is flawless. Naturally, in
676 | IPAKI ET AL.

products with more components, this situation becomes more 8 | CONCLUSION

complicated. However, there are limitations to a design project,
and further research may be needed to develop the product. In Designing for usability and safety has always been complex. In the
Table 6, we have listed the position of the mask design criteria combined results of this study, which led to a proposed design, a
according to the proposed design. modular design approach was used. Using this approach provided a
condition for supporting more users, and with its help, we were able
to provide the performance of adaptability with adjustability feature
7.3 | Limitations and future works in the design. Also, to develop the final design of the UVW mask, it is
necessary to re‐evaluate the criteria in usability tests in this study on
During the COVID‐19 pandemic, face‐to‐face access to users is other face masks that are widely used. Results from the usability test
limited. So, here, collected the usability data by convenience sampling of this study showed that the application of protocols to use
and internet system. This made it impossible observational studied FFP2–N95 and surgical masks cannot protect the individual against
the shape and anthropometry of the user's face and to differentiate the viruses alone. Studies on using disposable masks and their role in
the usability results. It may be useful and necessary to restudy this environmental pollution along with the results from the usability tests
issue and the impact of user gender and age on mask design in future indicate that drawbacks of design cannot be overcome only by fo-
research. cusing on behavioral issues. Therefore, in the conceptual design of
In cases where the health and safety of the user are desired, it mask UVW, it was suggested to focus on usability.
is necessary to conduct a specific anthropometric study of the
user community. Also, when patients inflicted with corona have CONFLIC T OF INTERESTS
been directly evaluated, there appears a change naturally in the The authors declare that there are no conflict of interests.
presented results, and the lack of determining target users due to
the inaccessibility to them was the most important limitation of ETHIC S S TATEM ENT
the present study. The role of design here is to apply engineering This investigation is done based on the Helsinki statement and ethical
interventions to prevent disease. The usability test in the most aspects of human research.
commonly used mask type, especially in developing countries,
showed us that it is significantly different from the ideal design. DATA AVAILABILITY STATEMENT
The costs limit the quality of the product and the circulation of The data that supports the findings of this study are available within
the medical product for the manufacturer, thus complicating the the article. Raw data available on request from the authors.
conceptual space of the design. Therefore, the main focus should
be on the design in such a way that in addition to the speed of ORC I D
production and production, the quality of the product is also high Bahram Ipaki https://orcid.org/0000-0002-1687-3602
and the price for the user is economical. The use of a modular
design approach in this study led to the introduction of a new RE F ER EN CES
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