Abstract
Objective: This research developed an environmentally sustainable alternative, called BioMask, to non-biodegradable polypropylene FFP2 masks, addressing the dual challenge of medical waste reduction and public health protection through interdisciplinary collaboration. Approach: The study employed Research through Design (RtD) methodology integrating expertise from design, nanomaterial science, fibre engineering, and medicine within a 15-month applied research project. RtD facilitated concurrent product-process development by using iterative prototyping as a common language across disciplines, enabling real-time problem-solving rather than traditional sequential development. The interdisciplinary consortium developed a novel sandwich material consisting of an electrospun cellulose acetate nanofibre filtration layer combined with viscose and banana fabric substrates, utilising design thinking to bridge technical knowhow across the disciplines mentioned. Results: The BioMask achieved key performance metrics that surpass conventional alternatives: 1. Filtration efficiency: 98.3% for 0.3-micron particles (vs. 65-94% for standard FFP2 masks) 2. Biodegradability: 100% decomposition in 83 days (vs. 0% for polypropylene masks) 3. Material composition: 99% biodegrahen possibledable components 4. Technology readiness: Achieved Technology Readiness Level 4 (TRL) validated with a provisional Portuguese patent protection. Interdisciplinarity: The collaborative approach revealed disciplinary synergies: nanomaterial scientists provided the core filtration technology, designers identified user-centred concerns and optimised morphology, fibre engineers ensured manufacturing feasibility, and medical professionals validated clinical applicability. Insights: This interdisciplinary process model provides transferable insights and a replicable structure for addressing complex sustainability challenges in medical product development. The approach demonstrates design thinking serving as a bridge between disciplines, translating laboratory innovations into commercially viable, environmentally responsible solutions. Broader impact: The output demonstrated a proof-of-concept utilizing nano material manufacturing with electrospinning and machine stitching the BioMask sandwich material achieving 25 functional prototypes, integrating banana fabric, cellulose acetate, and viscose. Future commercialization depends on scaling up manufacturing and achieving EN149 / FFP2 certification.
Keywords
Sustainability; Biodegradable; Medical product design; Interdisciplinary research
DOI
https://doi.org/10.21606/iasdr.2025.748
Citation
Chakraborty, S., Loyens, D., Aston, J., Jain, H., Ornelas, M.D.,and de Gouveia, R.H.(2025) Insights on designing a novel 99% biodegradable FFP2 BioMask through interdisciplinary applied research., in Chang, C.-Y., and Hsu, Y. (eds.), IASDR 2025: Design Next, 02-05 December, Taiwan. https://doi.org/10.21606/iasdr.2025.748
Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License
Conference Track
Track 8 - Circular/Sustainable Design
Insights on designing a novel 99% biodegradable FFP2 BioMask through interdisciplinary applied research.
Objective: This research developed an environmentally sustainable alternative, called BioMask, to non-biodegradable polypropylene FFP2 masks, addressing the dual challenge of medical waste reduction and public health protection through interdisciplinary collaboration. Approach: The study employed Research through Design (RtD) methodology integrating expertise from design, nanomaterial science, fibre engineering, and medicine within a 15-month applied research project. RtD facilitated concurrent product-process development by using iterative prototyping as a common language across disciplines, enabling real-time problem-solving rather than traditional sequential development. The interdisciplinary consortium developed a novel sandwich material consisting of an electrospun cellulose acetate nanofibre filtration layer combined with viscose and banana fabric substrates, utilising design thinking to bridge technical knowhow across the disciplines mentioned. Results: The BioMask achieved key performance metrics that surpass conventional alternatives: 1. Filtration efficiency: 98.3% for 0.3-micron particles (vs. 65-94% for standard FFP2 masks) 2. Biodegradability: 100% decomposition in 83 days (vs. 0% for polypropylene masks) 3. Material composition: 99% biodegrahen possibledable components 4. Technology readiness: Achieved Technology Readiness Level 4 (TRL) validated with a provisional Portuguese patent protection. Interdisciplinarity: The collaborative approach revealed disciplinary synergies: nanomaterial scientists provided the core filtration technology, designers identified user-centred concerns and optimised morphology, fibre engineers ensured manufacturing feasibility, and medical professionals validated clinical applicability. Insights: This interdisciplinary process model provides transferable insights and a replicable structure for addressing complex sustainability challenges in medical product development. The approach demonstrates design thinking serving as a bridge between disciplines, translating laboratory innovations into commercially viable, environmentally responsible solutions. Broader impact: The output demonstrated a proof-of-concept utilizing nano material manufacturing with electrospinning and machine stitching the BioMask sandwich material achieving 25 functional prototypes, integrating banana fabric, cellulose acetate, and viscose. Future commercialization depends on scaling up manufacturing and achieving EN149 / FFP2 certification.