Herein, 3D Array Technology LLC aims to develop a new type of nanostructure array (nanoarray) integrated microfibers to enable the medical masks with high filtration efficiency, low breathing resistance, and good antimicrobial capabilities. By integrating multifunctional nanoarray coatings onto the polypropylene microfibers through a scalable hydrothermal process, the surface area and roughness of the microfibers can be increased and the filtration efficiency of the masks for ultrafine particulate matters (PMs) can be enhanced. Meanwhile, antimicrobial agents can be loaded onto the nanoarrays, enabling the antimicrobial functions to prohibit the accumulation of microbials on the masks. Moreover, the excellent mechanical robustness of the nanoarrays can stabilize the supported antimicrobial agents, which helps to reduce the leaching and nanotoxicity issues. Furthermore, the enhanced PM filtration efficiency can make the masks with less materials to achieve the desired filtration efficiency, therefore, the wearers can breathe more comfortably with enhanced air flow. Finally, this proposed technology is highly compatible with the existing mask production lines, therefore keeping a low entry level in the existing market. The successful development of this project will help to establish the new design and standards for the next generation of masks and medical filtration equipment.
