Ashish Handa
Research Scholar
Dr B.R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India
Email ID – ashishhanda569@gmail.com
Introduction
When the COVID-19 pandemic struck, the world reached for the first line of defense it could trust — the N95 mask. But even as this five-layered shield became synonymous with protection, it also revealed its limitations: poor breathability, single-use design, and environmental waste. What if we could create a smarter mask — one that filters better, breathes easier and even cleans itself?
As part of my master’s research in textile engineering, I took on this challenge. The result is a reimagined N95 respirator that fuses nanotechnology, advanced polymers, and sustainability principles into a breathable armor — lighter, stronger, and potentially reusable.
The Five-Layer Revolution: More Than Meets the Mask
At the heart of the new design lies a carefully engineered five-layer structure. Gone is the traditional melt-blown-centric construction. In its place, nanofibrous membranes made from polyacrylonitrile (PAN), polyvinylidenefluoride (PVDF), and the high-strength polymer UHMWPE — all created via electrospinning, a cutting-edge process that spins fibres a thousand times thinner than a human hair.
These fibers don’t just block particles; they manipulate air flow. Their ultra-fine structure creates a tortuous path that traps aerosols, bacteria, and viruses with remarkable efficiency — all while keeping breathing resistance comfortably low.
In real-world terms? A face velocity as high as 9 cm/s — akin to brisk walking — still delivered a filtration efficiency of over 96.5% for PAN membranes, outclassing conventional materials. Even under this load, the pressure drop remained well within safe thresholds.
From Barrier to Bio-Weapon: Masks That Fight Back
But filtration is just the beginning. In a world where reusability and hygiene have become global imperatives, we turned to graphene oxide (GO) — the wonder material of the decade.
Infused into the nanofibers, GO doesn’t merely sit idle. Under sunlight or ambient indoor light, it springs into action — generating reactive oxygen species (ROS) that dismantle bacterial cell walls. This gives the mask self-decontaminating properties, significantly extending its lifespan without the need for ovens or chemical disinfectants.
In lab tests, our GO-embedded membranes demonstrated antibacterial activity against E. coli and Staphylococcus aureus, signaling a major leap forward in self-cleaning respiratory protection.
Redefining Breathability: Health Is in the Air
While filtration standards are well known — the “95” in N95 is shorthand for 95% filtration — what about what we breathe back in?
Our study also addressed carbon dioxide (CO₂) accumulation, an overlooked yet critical factor affecting wearer comfort and long-term health. Prolonged CO₂ re-inhalation has been linked to headaches, fatigue, and even cognitive decline.
By fine-tuning areal density and pore structure, we ensured CO₂ concentrations remained below the EN149 safe threshold of 1%, with our PAN-based respirator registering a modest 0.83% even under exertion. It breathes easier — and smarter.
Comparison of filtration efficiency and pressure drop of different respirators with NIOSH standards
| Parameters | Typical N95 Respirator | PVDF incorporated Respirator | PAN incorporated Respirator | NIOSH standards |
| Filtration efficiency (%) | 97.3 | 94.40 | 96.49 | 95 |
| Pressure drop (Pa) | 180 | 90 | 98 | 245 |
The Bigger Picture: Science in Service of Humanity
This research, supported by India’s National Textile Technology Mission and hosted at E-spin Nanotech, is more than a technological achievement — it is a statement.
A statement that innovation can arise from the Global South. That science can be compassionate. And that the humble face mask, often discarded and overlooked, can evolve into an intelligent tool — one that responds to our breath, to our movements, and even to light.
Toward a Sustainable Future
The environmental cost of billions of disposable masks is staggering. By engineering respirators that are reusable, self-cleaning, and made from smart nanomaterials, we open doors to a circular future — one where health security doesn’t come at the cost of ecological balance.
As the world prepares for future pandemics and rising pollution levels, it’s time to look beyond passive protection. The next generation of masks won’t just shield us — they will adapt, respond, and even heal.
Conclusion
The next-generation N95 isn’t just a mask—it’s a revolution woven from nanofibers and ingenuity. By replacing outdated melt-blown layers with electro spun PAN, PVDF, and UHMWPE nanomembranes, we’ve crafted a shield that filters 96.5% of pathogens while slashing breathing resistance. But innovation didn’t stop at filtration: graphene oxide turns sunlight into a weapon, self-decontaminating the mask and challenging the throwaway culture of pandemic waste.
Beyond blocking threats, this smart armor prioritizes wearer health, curbing CO₂ buildup to 0.83%—far below safety thresholds—even during exertion. With filtration efficiency surpassing NIOSH standards and pressure drop halved, comfort and protection finally coexist.
Supported by India’s National Textile Mission, this breakthrough proves that science from the Global South can redefine global resilience. The future of protection isn’t passive; it’s adaptive, sustainable, and alive. As pandemics and pollution loom, our respirator doesn’t just filter air—it filters fear.
References
- Handa, A., & Mukhopadhyay, A. (2025). To study the nanofiber enhanced composite respiratory masks for higher filtration performance and reusability. Journal of Industrial Textiles, 55. https://doi.org/10.1177/15280837251318744
- Handa, A., & Mukhopadhyay, A. (2024). Improved breathability and reusability with N95 mask. Journal of Asian Technical Textiles, July-Sept. 2024 module.
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About The author: Ashish Handa is a Ph.D. scholar in Textile Technology at Dr. B. R. Ambedkar National Institute of Technology, Jalandhar, with research focused on 3D weaving and nanofiber-based respiratory masks. He earned his M.Tech and B.Tech degrees from the same institute and gained industry experience at E-Spin Nanotech Pvt. Ltd., working on nanofiber membranes, and at RSWM Ltd., supervising textile production operations.