Fraunhofer Institute for Microstructure of Materials and Systems IMWS
Fraunhofer Institute for Microstructure of Materials and Systems IMWS

New generation of FFP2 masks combines protection, comfort, and sustainability

Respiratory masks have become an integral part of everyday life. Whether in healthcare, industrial occupational safety, or during global pandemics, they protect against pollutants and pathogens. However, some models have weaknesses in practice: they are uncomfortable, do not fit every face, and pollute the environment as waste. In the recently completed "BestComfort" research project, the Fraunhofer Institute for Microstructure of Materials and Systems IMWS in Halle (Saale), together with partners from industry, has developed an innovative FFP2 mask that is ergonomically optimized, offers maximum protection, and can also be recycled sustainably.

© Fraunhofer IMWS
The automated test bench developed at Fraunhofer IMWS as part of the BestComfort project enables the fit and tightness of respiratory masks to be assessed quickly, reproducibly, and without the need for costly test subject studies.

While FFP2 masks reliably filter particles, many commercially available models fail to adapt optimally to the diversity of human face shapes. This results in leaks that reduce the protective effect. In addition, most masks are made of several different materials, which makes single-type recycling almost impossible. The "BestComfort" project addresses this issue by combining ergonomic design with materials science innovation and sustainable product design.

During the two-year project period, novel mask components were developed based on extensive head and face analyses. The focus was on the nose and ear loops, which were designed and tested in different variants. These loops were designed to adapt individually to different face geometries, reduce pressure points, and significantly improve the seal, thus increasing not only wearing comfort but also the filtering effect. At the same time, the Fraunhofer team worked with A+M GmbH and PORTEC GmbH to develop a so-called monomaterial concept. All mask components are made of polymer-based materials such as polypropylene or polypropylene-based materials. This means that the masks can be completely recycled after use, which makes a significant contribution to sustainability.

Modern manufacturing processes such as 3D printing, vacuum casting, and injection molding were used to test the new concepts in a practical setting. These methods made it possible to quickly implement various designs and produce functional prototypes. The mask demonstrators were then tested in extensive trials. Everyday situations and physical stress were simulated, and physiological tests were carried out to measure heat and moisture development during wear.

A central element of the research work at Fraunhofer IMWS was the development of an automated measuring station for evaluating the fit and tightness of the masks. The test bench, which complies with DIN EN 149:2001, "enables us to collect objective measurement data on mask performance without having to rely on costly and time-consuming test studies in every case. This is a major advantage. This automation contributes significantly to increasing efficiency in product development and allows for reproducible, standardized evaluation under realistic conditions," says Annika Thormann, project manager at Fraunhofer IMWS. In addition, the materials science expertise of Fraunhofer IMWS enables in-depth characterization of the materials used down to the microstructure level. Modern analysis techniques were used to examine the mechanical, thermal, and microstructural properties of the mask components. "In this project, we and our partners have succeeded in developing a mask that combines protection, comfort, and sustainability in equal measure. This demonstrates that high-tech materials research and practical development can go hand in hand," adds Thormann.

The project results have already been presented at international trade fairs such as formnext 2024 in Frankfurt and rapidtec 2025 in Erfurt, where they met with great interest from trade visitors and industry. Initial discussions with potential partners also open up promising prospects for further development and market launch.

(October 15, 2025)