Development of a virtual fit analysis method for an ergonomic design of pilot oxygen mask

In the ergonomic design of wearable products such as an oxygen mask, systematic design methods including the analysis of anthropometric information, evaluation of fit, and product design need to utilize 3D human scan data. The present study intends to develop a virtual fit analysis method that generates an ergonomic shape of an oxygen mask for fighter pilots based on 3D facial scans. The proposed virtual fit analysis method enables iteratively to revise the shape of an oxygen mask until an appropriate level of fit between the mask and a group of pilot faces is achieved. The proposed method of virtual fit analysis and design optimization was applied to find ergonomic shapes of oxygen masks for four size categories (small narrow, medium narrow, medium wide, and large wide) to accommodate 336 pilots of the Republic of Korea Air Force. The virtual fit analysis results in the study showed that the revised oxygen mask shapes achieved significantly higher accommodation percentages (4.8~88.7%) at facial areas (nasal root, nasal side, cheek, and chin) compared to the existing oxygen mask shapes. The proposed method can be applied to develop an ergonomic product design that fits the face and other human body parts.