Autors: Ivanova, M. D., Angelova, R. A.
Title: From Comfort to Protection: Quantitative Comparison of Fit and Air Permeability in Textile Masks and Respirators
Keywords: air permeability, comfort, ergonomic design, face mask, fit factor, protection, respirator, sealing, textile structure

Abstract: The present study examines the influence of material and structural parameters on the fit and air permeability of textile face masks, surgical masks, and certified respirators. Nine samples were tested using the AccuFIT 9000 for quantitative fit factor (FF) measurements and the FX-3340 MinAir for air permeability in both airflow directions. Results show that increased thickness moderately improves FF, supporting better facial sealing. However, mass per unit area and bulk density show weak or no correlation with FF. Air permeability correlates weakly and negatively with FF, especially during exhalation, but remains essential for wearer comfort. Notably, some textile masks outperformed certified respirators in terms of fit, highlighting the importance of design, elasticity, and edge sealing. The findings suggest that effective mask performance depends on more than filtration materials or certification levels. A balanced design combining breathability, structural optimisation, and ergonomic fit is essential for both comfort and protection. These insights can guide the development of more effective reusable and disposable face coverings, particularly in aerosol-rich environments.

References

  1. Adanur S. Jayswal A. Filtration mechanisms and manufacturing methods of face masks: An overview J. Ind. Text. 2022 51 (Suppl. 3) 3683S 3717S 10.1177/1528083720980169
  2. Angelova R.A. Velichkova R. Sofronova D. Markov D. Dimova M. Simova I. Air permeability of protective face masks Proceedings of the 2023 XXXIII International Scientific Symposium Metrology and Metrology Assurance (MMA) Sozopol, Bulgaria 7–11 September 2023 IEEE London, UK 2023 1 5
  3. O’Kelly E. Arora A. Pirog S. Ward J. Clarkson P.J. Comparing the fit of N95, KN95, surgical, and cloth face masks and assessing the accuracy of fit checking PLoS ONE 2021 16 e0245688 10.1371/journal.pone.0245688 33481870
  4. Knobloch J.K. Franke G. Knobloch M.J. Knobling B. Kampf G. Overview of tight fit and infection prevention benefits of respirators (filtering face pieces) J. Hosp. Infect. 2023 134 89 96 10.1016/j.jhin.2023.01.009
  5. Pandey L.K. Singh V.V. Sharma P.K. Meher D. Biswas U. Sathe M. Ganesan K. Thakare V.B. Agarwal K. Screening of core filter layer for the development of respiratory mask to combat COVID-19 Sci. Rep. 2021 11 10187 10.1038/s41598-021-89503-x
  6. Kwong L.H. Wilson R. Kumar S. Crider Y.S. Reyes Sanchez Y. Rempel D. Pillarisetti A. Review of the breathability and filtration efficiency of common household materials for face masks ACS Nano 2021 15 5904 5924 10.1021/acsnano.0c10146
  7. Zhang T. Zhang T. Liu S. A modified surgical face mask to improve protection and wearing comfort Buildings 2022 12 663 10.3390/buildings12050663
  8. Chiera S. Cristoforetti A. Benedetti L. Nollo G. Borro L. Mazzei L. Tessarolo F. A simple method to quantify outward leakage of medical face masks and barrier face coverings: Implication for the overall filtration efficiency Int. J. Environ. Res. Public Health 2022 19 3548 10.3390/ijerph19063548
  9. Otrisal P. Bungau C. Obsel V. Melicharik Z. Tont G. Selected respiratory protective devices: Respirators and significance of some markings Sustainability 2021 13 4988 10.3390/su13094988
  10. Lee K.P. Yip J. Kan C.W. Chiou J.C. Yung K.F. Reusable face masks as alternative for disposable medical masks: Factors that affect their wear-comfort Int. J. Environ. Res. Public Health 2020 17 6623 10.3390/ijerph17186623
  11. Duncan S. Bodurtha P. Naqvi S. The protective performance of reusable cloth face masks, disposable procedure masks, KN95 masks and N95 respira-tors: Filtration and total inward leakage PLoS ONE 2021 16 e0258191 10.1371/journal.pone.0258191
  12. Wang C. Xu J. Zhai H. So L.K. Guo H. Mapping full-range infection transmission from speaking, coughing, and sneezing in indoor environments and its impact on social distancing J. Hazard. Mater. 2025 490 137782 10.1016/j.jhazmat.2025.137782
  13. Morris H. Murray R. Healthcare, hygiene, and personal protective equipment (PPE) Medical Textiles CRC Press Boca Raton, FL, USA 2021 261 310
  14. Song J.Y. Kim S. Park J. Park S.M. Highly efficient, dual-functional self-assembled electrospun nanofiber filters for simultaneous PM removal and on-site eye-readable formaldehyde sensing Adv. Fiber Mater. 2023 5 1088 1103 10.1007/s42765-023-00279-3 37235136
  15. Oner E. Seçkin A.Ç. Egeli D. Seçkin M. Investigation of the thermal comfort properties of masks used during the COVID-19 pandemic Int. J. Environ. Res. Public Health 2022 19 11275 10.3390/ijerph191811275 36141548
  16. Zhuang Z. Bergman M. Lei Z. Niezgoda G. Shaffer R. Recommended test methods and pass/fail criteria for a respirator fit capability test of half-mask air-purifying respirators J. Occup. Environ. Hyg. 2017 14 473 481 10.1080/15459624.2017.1296233 28278067
  17. Chua M.H. Cheng W. Goh S.S. Kong J. Li B. Lim J.Y.C. Mao L. Wang S. Xue K. Yang L. et al. Face masks in the new COVID-19 normal: Materials, testing, and perspectives Research 2020 2020 7286735 10.34133/2020/7286735
  18. Regli A. Sommerfield A. von Ungern-Sternberg B.S. The role of fit testing N95/FFP2/FFP3 masks: A narrative review Anaesthesia 2021 76 91 100 10.1111/anae.15261
  19. Rengasamy S. Miller A. Eimer B.C. Shaffer R.E. Filtration performance of FDA-cleared surgical masks J. Int. Soc. Respir. Prot. 2009 26 54
  20. Wang D. You Y. Zhou X. Zong Z. Huang H. Zhang H. Yong X. Cheng Y. Yang L. Guo Q. Selection of homemade mask materials for preventing transmission of COVID-19: A laboratory study PLoS ONE 2020 15 e0240285 10.1371/journal.pone.0240285
  21. AccuTec-IHS, Inc AccuFIT 9000 Quantitative Respirator Fit Tester—Product Data Sheet. Retrieved from Manufacturer’s Website 2024 Available online: https://accutec.com/wp-content/uploads/2024/02/AccuTec_Data-Sheet_Template-9000-1.pdf (accessed on 19 August 2025)
  22. ISO 1773:2002 Textiles—Determination of Thickness of Textile Fabrics International Organization for Standardization ISO Geneva, Switzerland 2002
  23. ISO 5084:1996 Textiles—Determination of Thickness of Textiles and Textile Products International Organization for Standardization ISO Geneva, Switzerland 1996
  24. ISO 9237:1995 Textiles—Determination of the Permeability of Fabrics to Air International Organization for Standardization ISO Geneva, Switzerland 1995
  25. Wang A.B. Zhang X. Gao L.J. Zhang T. Xu H.J. Bi Y.J. A review of filtration performance of protective masks Int. J. Environ. Res. Public Health 2023 20 2346 10.3390/ijerph20032346
  26. Oberg T. Brosseau L.M. Surgical mask filter and fit performance Am. J. Infect. Control 2008 36 276 282 10.1016/j.ajic.2007.07.008
  27. Chaaban O. Balanay J.A.G. Sousan S. Assessment of best-selling respirators and masks: Do we have acceptable respiratory protection for the next pandemic? Am. J. Infect. Control 2023 51 388 395 10.1016/j.ajic.2022.06.024

Issue

Textiles (Switzerland), vol. 5, 2025, Switzerland, https://doi.org/10.3390/textiles5040059

Вид: статия в списание, публикация в издание с импакт фактор, публикация в реферирано издание, индексирана в Scopus и Web of Science