Finding a solution to the N95 mask shortage

Melinda Harman of Clemson University is volunteering her time to explore how hospitals could wash and sanitize medical masks without having to ship them elsewhere or buy an expensive piece of equipment.

A device that Harman designed to hold multiple N95 masks is central to her idea. It would help ensure the masks maintain their shape while being washed so that they continue to fit securely around the mouth and nose, said Harman, an associate professor of bioengineering and director of Clemson University’s Medical Device Recycling and Reprocessing program, or GreenMD. 

The masks help prevent healthcare workers from inhaling the novel coronavirus that causes COVID-19 and have been in short supply since the pandemic began.

As part of her work, Harman said she has engaged three leading healthcare companies that offer expertise in detergents and decontamination. She is testing different kinds of detergents to find the best solution for cleaning mucus and proteins from the masks. 

The detergents are commercially available and already used by hospitals to clean other types of medical equipment.

Harman said that her goal is “to validate a cleaning process that is compatible with existing capabilities and equipment commonly available at hospitals in South Carolina and worldwide.”

The challenge is “to avoid interfering with mask performance, while effectively cleaning the masks without degrading their filtering capacity,” she said.

Harman added, “Working with innovative industry partners is a considerable advantage, with everyone on the team willing to contribute a potential solution. They are providing reliable products that are already proven to meet routine reprocessing challenges in healthcare delivery.”

Harman said one of the advantages to her approach is that many hospitals already have the ability to clean medical equipment, even if they aren’t yet applying it to the masks. That means hospitals wouldn’t need to buy any capital equipment, she said.

Further, the masks would stay at the hospital, reducing travel time, the risk of spreading contamination outside of the hospital and the additional burden on an already-stressed logistics system, Harman said.

“The technology I’m working on is meant to be used broadly, compatible with existing reprocessing practices that are already in hospitals,” Harman said. “It’s intended for rapid deployment in health care settings, and it’s meant to be compatible with any sterilization system.” 

Harman added, “Cleaning masks before sterilization enables more masks to be reused Right now, guidelines for sterilization require N95 masks to be inspected and discarded if they are ‘soiled.’ My idea is to reliably clean masks to remove both the visible and ‘invisible’ soils, making the entire reuse process safer.”

Martine LaBerge, chair of the Department of Bioengineering, said that Harman is well qualified to lead the work.

Harman has conducted extensive research into reuse and reprocessing of medical equipment. As director of GreenMD,  she engages students in industry-driven research targeting healthcare needs in South Carolina and broader global health challenges. GreenMD is the nation’s only engineering-focused program for medical device design targeted for reprocessing and reuse.

“Dr. Harman has built a career on developing innovative ways to reprocess and reuse medical equipment that is normally disposable, which uniquely positions her to have a global impact,” LaBerge said. “I thank her for her service to South Carolina, the nation and the globe as we join together in the face of the unprecedented challenges posed by COVID-19.”

Harman said that if her idea works, used masks would be sent to central sterilization facilities within hospitals. The device she designed would hold the masks while they are cleaned.  After cleaning, the masks would go through a separate sterilization process to get rid of any lingering microorganisms, including coronavirus.

The mask-holder that Harman designed could be 3D-printed, she said. However, she is focusing on more rapid manufacturing approaches using common acrylic materials. The technology could be readily adapted in hospitals from South Carolina to India, Harman said.

She recently disclosed the technology to the Clemson University Research Foundation, setting it on the path to commercialization and raising the potential for widespread use.

 Harman said what’s been most interesting to her is that her previous work with resource-poor countries has come home to the United States, with disrupted supply chains and inadequate supplies at the point of need.

 “That’s exactly the situation we’ve been working on with other countries,” Harman said. “For me that’s just been a startling change. It’s been amazing to see how many people have become interested in the topic of safe and sustainable reuse and how many unique solutions they come up with. I hope that creative energy continues, because it can solve a lot of global health problems.”