A study to determine the three-dimensional (3D) facial shape characteristics for a successful FFP3 mask fit

A reported 20% of dental staff will fail their fit test for a disposable FFP3 respirator. This needs to be factored into future pandemic workforce and PPE supply planning. At present there are no scientifically or universally accepted facial shape criteria to design and produce facial masks that will fit the entire work force. This study presents differences in facial shape, volume and surface area between individuals who passed on several FFP3 masks (pass group) and participants who passed on only one FFP3 mask (fail group). Three dimensional images of 50 individuals, 25 in each group, were taken at rest and at maximum smile using a DI4D SNAP 6200 camera system. The images were processed, and four "average faces" were produced-pass group at rest, fail group at rest, pass group at maximum smile and fail group at maximum smile. Simple Euclidian linear and angular measurements, geodesic surface distances and volume and surface area enclosed within the mask were analysed. The results of the study show that individuals who are more likely to pass a mask fit test have longer faces, wider mouths, greater geodesic surface distances and a greater volume and surface area of soft tissue enclosed within the mask boundary. This would suggest that some manufactures masks may be too large, and they need to reduce the size of their masks or produce a category of sizes, accepting the fact that one size does not fit all.