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Direct Digital Manufacturing of a Customized Face Mask

Direct Digital Manufacturing (DDM) is considered by many as one of the most promising approaches towards cost- and time-efficient mass customization. Compared to conventional manufacturing systems, DDM systems are not as common and incorporate several distinctive features, such as higher flexibility in product form and structure, lower economies of scale and higher potential for decentralized production network. The initial design phase of a DDM production system, where very important in term of efficiency and quality, decisions are made, is a relatively unexplored topic in the relevant literature. In the present study, the corresponding issues are investigated through a case study involving the direct digital production of a customized reusable face mask (respirator) for medical use. Investigated system design aspects include product, process, and facility design. Based on data generated through manufacturing tests, a preliminary cost analysis is performed and several scenarios regarding production throughput and facility planning are examined. According to the results, DDM of custom-made face masks is, to a large extent, technically and economically feasible. Interestingly, considering the whole process, a large part of production cost is associated with labor and materials. Finally, evidence for a fundamental trade-off between manufacturing cost and speed/flexibility is identified, implying that different implementations of DDM systems can be realized depending on strategic operational objectives.