Flexible Nanoporous Template for the Design and Development of Reusable Anti-COVID-19 Hydrophobic Face Masks

Nazek Elatab, Nadeem Qaiser, Huda Badghaish, Sohail F. Shaikh, Muhammad Mustafa Hussain

Research output: Contribution to journalArticlepeer-review

129 Scopus citations


Since the outbreak of the severe respiratory disease caused by the novel coronavirus (COVID-19), the use of face masks has become ubiquitous worldwide to control the rapid spread of this pandemic. As a result, the world is currently facing a face mask shortage, and some countries have placed limits on the number of masks that can be bought by each person. Although the surgical grade N95 mask provides the highest level of protection currently available, its filtration efficiency for sub-300 nm particles is around 85% due to its wider pore size (∼300 nm). Because the COVID-19 virus shows a diameter of around 65-125 nm, there is a need for developing more efficient masks. To overcome these issues, we demonstrate the development of a flexible, nanoporous membrane to achieve a reusable N95 mask with a replaceable membrane and enhanced filtration efficiency. We first developed a flexible nanoporous Si-based template on a silicon-on-insulator wafer using KOH etching and then used the template as a hard mask during a reactive ion etching process to transfer the patterns onto a flexible and lightweight (
Original languageEnglish (US)
Pages (from-to)7659-7665
Number of pages7
JournalACS Nano
Issue number6
StatePublished - May 20 2020

Bibliographical note

KAUST Repository Item: Exported on 2020-10-01
Acknowledged KAUST grant number(s): OSR-2015-Sensors-2707, OSR-2016-KKI-2880.
Acknowledgements: This publication is based upon work supported by the King Abdullah University of Science and Technology (KAUST) Office of Sponsored Research (OSR) under Award No. Sensor Innovation Initiative OSR-2015-Sensors-2707 and KAUSTKFUPM Special Initiative OSR-2016-KKI-2880. The authors would like to acknowledge Prof. Aftab Hussain, Prof. Jhonathan Prieto Rojas, and Dr. Galo Torres Sevilla and Maurilio Matracia who have worked on the release of the template.


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