Dual-Durometer Respirator Redesign

I already have Rev-B drawings and core engineering specs for a reusable silicone respirator, but the first prototype exposed a durometer mismatch that lets air leak. I need the facepiece geometry and seal architecture re-worked so the mask seals perfectly every time a user talks, turns, or sweats.

Here is what matters most:
• The overriding goal is to enhance sealing performance.
• Comfort tweaks are required on the seal lip and the nose bridge—both will shift to a softer Shore grade while the main body stays firmer.
• The construction remains dual-durometer LSR; please specify exact Shore values, parting lines, and over-mold strategy.

Cartridge interface:
The 6 × 5 cm four-layer filter stack must snap in and out without tools. I’m after a custom snap-fit / bayonet hybrid that survives at least 500 replacement cycles, maintains an airtight seat, and can be molded without heroic undercuts.

Deliverables (all native SolidWorks 2022 + neutral STEP):
1. Updated 3-D CAD of the facepiece, seal regions, and cartridge interface.
2. Drawings with full GD&T and material call-outs ready for a silicone tooling vendor.
3. Brief FEA or equivalent rationale showing uniform compression on the new seal.
4. Assembly instructions or an exploded view so a prototype house can build the next sample without ambiguity.

If you have deep experience in LSR over-molding, snap-fit design, and respirator or medical wearables, let’s talk—I’m ready to move to prototype round two as soon as the files pass review.