Case Study: Breathe99 achieves rapid prototyping and launch of an ergonomic, sealable respirator with Stratasys PolyJet 3D Printing

Startup launches ergonomic face mask with PolyJet 3D printing

Breathe99, a startup formed to build a reusable, industrial‑grade respirator (the B2), struggled to design and test a sealable, ergonomic mask that fits many face shapes while remaining durable and comfortable. To produce realistic, multimaterial prototypes that could show investors and validate fit and function, Breathe99 turned to Stratasys (working with reseller AdvancedTek) and its PolyJet technology using Agilus30 on the J Series.

Stratasys’ PolyJet solution allowed AdvancedTek to 3D print flexible, multimaterial B2 prototypes in as little as a day, enabling rapid iterations with adjustable durometers, sizes and assembly options. The durable prototypes supported hands‑on user testing and stakeholder reviews, accelerated design improvements and marketing, and helped bring the B2 mask to market—demonstrated by same‑day prototypes and multiple iterations completed in just a few days thanks to Stratasys.

Breathe99

Max Bock-Aronson

Founder