Modular and programmable breathing phantom station for accelerated degradation testing of industrial respirator...

This work presents the development and validation of a modular and programmable breathing phantom station designed for accelerated degradation testing of industrial respirator filters. The system replicates human respiratory patterns using a mechanical ventilator and a custom-built humidification unit, enabling controlled exposure of filters to respirable dust particles (≤10 µm) within a sealed contamination chamber. Filter saturation is assessed through pre- and post-exposure weight measurements, providing a direct and quantifiable evaluation method. Experimental validation was conducted through an accelerated degradation test using two filter samples to assess reproducibility. The experiment used a particulate concentration of 104 mg/m³, corresponding to 10.4 times the OSHA permissible exposure limit, allowing accelerated testing under physiologically realistic breathing conditions. Over a one-week exposure period, P100 filters exhibited a progressive mass increase of approximately 1.3 g from an initial weight of 13 g, reaching a clear gravimetric saturation plateau. Results demonstrated strong reproducibility across different respiratory profiles and alignment with manufacturer-defined saturation limits. The platform provides a scalable and cost-effective tool for respiratory filter testing, with potential adaptability to various respirator designs and materials, filter types and airborne contaminants. Full hardware documentation, including schematics, the bill of materials, and the control procedure, is made available to support replication and further innovation within research and occupational health and safety.