Orbis Unveils Washable, Thermoformed PE Mask with Replaceable HEPA Filter – A Promising N95 Alternative

Introducing the BiOAID Mask

Orbis (bioaid.us), a California‑based company originally focused on electric drivetrain systems, has pivoted to health technology. The result is a thermoformable mask that combines a polyethylene (PE) shell with a replaceable HEPA‑type filter. Designed as a cost‑effective alternative to melt‑blown polypropylene (PP) N95 respirators, the BiOAID mask can be washed with soap and water or in the top rack of a dishwasher—something conventional N95s cannot do.

Manufacturing Strategy

Orbis is offering its proprietary molds, dies, and manufacturing instructions to thermoforming companies under a nominal licensing program. The company plans to partner with contract manufacturers for the initial launch to guarantee product quality, then expand licensing after a 45‑day market assessment.

Materials & Design for Performance

• Shell: Low‑density polyethylene (LDPE) combined with polyvinylidene fluoride (PVDF) sheet to provide flexibility and a secure face seal—key for NIOSH and FDA compliance.
• Filter Cartridge Clip: PET, which requires only two dimple‑fabrication steps, keeping production costs low.
• Filter Media: HEPA or MERV‑13 materials (common in vacuum bags and furnaces) composed of borosilicate glass fibers or PP fibers with up to 5% acrylic binder—shown to match melt‑blown PP N95 efficacy.

The front of the mask features strategically placed breathing holes backed by a two‑inch square of standard HEPA filter material, ensuring both airflow and protection.

Reusability & Cost Efficiency

The BiOAID mask’s washable shell and replaceable filter mean users can clean the mask with soap and water or a dishwasher, dramatically reducing the per‑use cost. When produced at volume, the price is expected to align with standard N95 respirators.

Future Outlook

Although the mask is not yet N95‑certified, Orbis anticipates certification shortly after market launch. Marcus Hays, co‑founder and co‑inventor, notes that thermoforming companies play a crucial role in scaling protection for communities worldwide.