What is a Melt-Blown filter???

Surgical Masks

Surgical masks are generally speaking a 3-ply (three layer) design, with 2 sheets of “non-woven” fabric sandwiching a “melt-blown” layer in the middle. It’s the melt-blown layer that provides the filtering capability. A melt-blown material is also used in respirators, and thus you can imagine it’s more expensive and hard to come by recently, due to demand.

{Image of the melt-blown filaments under microscope come from mdpi.com}

The melt-blown fabric is made by melting a plastic, then blowing it from either side at high velocity onto a rotating barrel. Done right, this results in a fabric composed of tiny filaments. For a more technical (!) explanation of the process – see here.

{Diagram of melt-blown machinery (left) comes from Erdem Ramazan’s book, and the image of melt-blowing in progress (right) comes from 4FFF on wikipedia}

Not all melt blown fabric has the same filtering capability, some are better than others. Unfortunately we can’t test the filtering capability of the melt-blown layer without specialized knowledge and equipment. What we can do, however, is at least check that the melt-blown layer is present.

Below I show an example of a surgical mask (left) that came without the melt-blown layer. You can imagine that, given the extra cost and current scarcity of melt-blown fabrics, manufacturers might cut corners with this layer, so it’s worth keeping an eye on.

Choosing surgical masks that have been tested according to a set of standardized test methods (ASTM F2100, EN 14683, or equivalent) will help avoid low quality products. The ASTM standard for surgical masks (particularly levels 2 & 3) are primarily focused around fluid resistance during surgery. These higher levels don’t offer much extra in the way of protection from Covid-19 under non-surgical conditions.

Goo&Smith of the Melt-blown filter 25/GSM