B2 Mask — Max Bock-Aronson

The B2 Mask is a low-waste, protective respirator designed for comfortable, daily use. As the technical co-founder of Breathe99, I owned the full product lifecycle, from initial concept development through manufacturing, distribution, and product support. As CEO, I managed a small, distributed team to navigate supply chain challenges, digital marketing blocades, and distribution complexities to ship over 28,000 masks to customers in 18 different countries and be named one of TIME Magazine's Best Inventions of 2020. The company was sold to Armbrust American in 2023.

My journey to building Breathe99 began while I was living and studying in Singapore in 2013. "Wow… My lungs actually hurt," I remember thinking while encountering air pollution during one of my runs on the Nanyang Technological University campus. Simultaneous to this experience, an air pollution engineering course taught me the physics of filtration and that common street masks did little to protect against harmful airborne particles. These experiences inspired me to design a thoughtfully-designed mask for urban commuters in need of better protection.

Process

The Atlantic

Initial Observation + Hypothesis

Seasonal smog is a common occurence in Southeast Asia. However, poor public education regarding proper use of Personal Protective Equipment (PPE) results in diminished public health. These insights led to a question: How might we develop a 'style' respirator that provides the protection of an N95, but that people actually want to wear?

Concept Generation

Concepting work began with sketching, paper prototyping, and clay to explore the balance between a low-profile design and a comfortable air-tight seal.

CAD Development

I modeled and refined concepts in SolidWorks (2D, 3D, Surfacing, Assemblies) to create parametric models that could be scaled to different sizes using anthropomorphic data and head models from both public and private sources.

Prototyping

I utilized various 3D printing technologies (FDM, SLA, MJF, CLIP) and traditional and insert casting (urethane, silicone) to prototype the organic, flexible shapes required for the facepiece.

Fit Testing

The team and I worked in collaboration with Anthrotech to design and run user studies using OSHA-approved fit testing protocols and a Portacount Quantitative Fit Testing device.

Transfer to Manufacturing + IP

Working closely with a locally-based contract manufacturer (CM), I created 2D drawing packages and refined all components for injection molding production (DFM, draft, shutoff geometry, gating and ejection strategies, and more). I also worked with a patent attorney to file provisional, utility, and design patents.

Filtration Testing

I worked with our director of operations to navigate supply chain disruptions and source high-quality electrostatically charged filter media for the B2 Mask. Together, we partnered with a research fellow at the University of Minnesota to conduct flow testing using NIOSH testing protocols for flow rate and particle loading.

Production + Molding

I continued to manage the relationship with our CM through tool making, mold trials, first sample inspection, and part approval process (FAI/PPAP). Along with the CM, I worked with a plastics specialty firm to sample and select resins and colorants appropriate for extended skin contact.

Design Refinement + Improvement

Working with the team, I managed continuous improvement efforts to support the B2 Mask upon launch, including filter breathability and an improved 3D knitted overlay for the mask.

Distribution + Recognition

Ultimately, the B2 Mask was named one of TIME Magazine's Best Inventions of 2020, propelling the business to sell and ship over 28,000 masks and its eventual sale to Armbrust American in early 2023.

A sustainable and protective elastomeric mask named one of TIME Magazine's Best Inventions of 2020.