Hydro Tube Mask

Hydro-Tube Mask — Consumer Wearable | USC Academic Project

SolidWorks · TRIZ · FR-DP Mapping · Kano Modeling · DFA · Material Selection · User-Centered Design

A hydration system designed to integrate seamlessly into existing firefighter respirator masks — solving a real operational problem where first responders cannot hydrate during wildfire operations without removing protective gear.

Problem framing Firefighters in wildfire operations face dehydration risk because standard respirator masks offer no hydration access. Removing the mask to drink exposes them to smoke and toxic air. The design challenge was to integrate a hydration pathway into an existing mask architecture without compromising seal integrity, safety, or usability under extreme conditions.

Concept development Applied TRIZ, FR-DP mapping, and Kano modeling within the Innovative Design Thinking framework to systematically generate and evaluate concepts. This process led to a partially uncoupled design — a flask-mounted tube system with a mouthpiece attachment that routes hydration through the mask body without breaking the respiratory seal.

Mechanical design and sealing Built the full assembly CAD in SolidWorks. The sealing interface uses a press-fit O-ring mechanism at the flask-to-tube junction, sized to standard OEM tube dimensions for compatibility with existing equipment. DFA principles drove the assembly architecture — minimizing part count and ensuring the system could be donned and doffed with gloved hands under field conditions.

Material selection Selected stainless steel over aluminum and titanium through a structured cost-to-strength and thermal analysis. Aluminum was eliminated despite its weight advantage because of its thermal conductivity — in a high-heat environment, an aluminum flask would transfer heat to the water, delivering warm water to the user. The 100–150g weight penalty of stainless steel was deemed acceptable against this safety and comfort trade-off.

Outcome Proof-of-concept design validated for mechanical feasibility, sealing performance, and assembly logic. GD&T engineering drawings, BOM, and CMF specifications produced for manufacturability review.