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Early biometric 3D study
Early biometric 3D study
Early strap angle study
Patterning in paper-
Digital patterning
Early maquette for pattern development.
Stitched samples-
Vacuum forming composite layups with breathable Bemis PU Hotmelt film.
Vacuum forming composite layups with breathable Bemis PU Hotmelt film.
Cutting Vacuum formed composite layups out.
Hot air tape construction trials-
Hot air tape construction trials-
Exploration into composite layups with stiff non-woven composite which are cut for breathability..
Compression inmolding fabric. Mold has ability to cycle both hot and cold.
Compression molded trials.
Compression multiple trials failure due to over melt.
First batch of engineering samples for fit-
Exploration of Velcro and adjustment systems-
Laser cutting hole for fan-
Exploration of Velcro and adjustment systems-
Laser cut edge stabilized with TPU film.
Fit trials for lasered parts-
Compression molded knit parts- determining optimum knits for breathability.
Final assembly trials with early fan parts-
Compression multiple trials failure due to over melt.
Revised 3-D based on 2D patterning-
Compression molded fabric exploration-
Compression molded fabric exploration-
The beautiful mold with holding pins!
View of the compression mold parts!
Knitting final custom fabric with proprietary mix of heat activated yarns-
Knitting final custom fabric with proprietary mix of heat activated yarns-
Laser cut jig.
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Philips knit & powered face mask N95

Awarded IF DESIGN Award. Engaged by Phillips to design, develop and source the manufacturing of the knit mask. Phillips had a design direction, and contracted me to help realize the complex 3D form in a knit breathable material. We initially tried to pattern the form, and then developed a process for compression molding a custom developed knit fabric with a high modulus through TPU yarn. Through many iterations of composite fabrics and different hotmelt layups, we dialed in a final material and process to achieve the deep shapes.

Available
Freelance
M Coleman Horn
Founder and Principle Designer at Phyla, Inc. San Francisco, CA