Forged Air

Rethinking the Respirator

A white health N95 face mask with yellow and gray straps against a gray background.

Protection that performs under pressure

PPE systems are broken, cost prioritized over performance, leaving first responders focused on their gear instead of the job. ForgedAir rethinks the respirator as a system of clarity, confidence, and control. With 99.97% filtration, vocal clarity, fit confirmation, and all-day comfort, it keeps users focused on the work that matters.

Services:

  • Strategic Insights

  • Industrial Design

  • Technology Integration

  • CAD Design

  • Prototyping

Emergency medical personnel in protective gear working in the back of a medic truck, preparing medical equipment.
A man wearing safety goggles, a face mask, and a firefighter uniform with an embroidered emblem, is inside a vehicle, holding a white device in his hand, with trees visible outside the vehicle window.
A female paramedic adjusting her face mask while wearing a black uniform with reflective yellow stripes and a patch that reads 'Paramedic Services' on her sleeves, indoors with white panel walls in the background.

Research exposed a system that breaks under pressure, unclear communication, uncertain protection, painful fit and constant fogging. The burden shifts to the user, pulling focus from critical work.

Seven facemasks in green, light blue, blue, purple, darker blue, red, and yellow displayed on a white mannequin head, illustrating different colors.
Close-up of an artificial respirator or N95 mask with yellow honeycomb-shaped interior structure and yellow straps.

Seven interchangeable face flanges deliver a precise fit across diverse users.

Close-up of a white device with a yellow component labeled 'FFR' and 'BreatheSafe' illuminated.

Breathing data, transformed into real-time safety, enabled by patented technology.

A white N95 respiratory mask with yellow straps and a pink indicator light, displayed against a light background.
A yellow industrial or construction tool or device with a large gray circular component and various openings and attachment points.

BreatheSafe. An air pressure sensor monitors breathing and seal integrity, delivering real-time fit and filter validation.

Smartphone screen displaying the ForgeAir app, showing a filter status at 85% with a suggested change next week, with saved filters and a seal test indicator at the bottom.
Smartphone screen displaying a health app with a face seal test result of PASS 197/200, indicating the face seal test is complete, and showing monthly and 3-day breathing average data.
Mobile app screen showing air quality monitoring with a focus on seal breach alert during breathing analysis. Graph plots seal breach and baseline levels from 8:30 to 10:36 AM.
A man wearing safety goggles and a face mask.
A person wearing a dark blue shirt holding a white disposable face mask with the label 'FORGED Air' printed on it.
Spectrogram comparing sound frequencies of three different breathing conditions: mask off, traditional P100, and forged air, showing different frequency patterns and intensities.
Bar graph comparing percentage of mask off, traditional P100, and forged air. Mask off shows 100%, traditional P100 around 60%, forged air approximately 80%, with a statistically significant difference between traditional P100 and forged air (P<0.05).

Breath Easier, Speak Clearer.
Flat, nanofiber filtration replaces bulky cartridges, boosting audibility by 25% and cutting filter costs by 75%.

A mannequin head wearing a white and yellow FFR N95 respirator mask and a clear face shield against a gray background.
A modern transparent chair with a clear plastic backrest and chrome-plated metal legs.

A patented, removable visor provides fog-free, seamless eye protection, isolated from skin contact.

Close-up of two medical contact lenses with white and yellow frames and grey, yellow, and white elastic bands labeled 'S', 'M', and 'L'.

Clear size indicators help users dial in fit, reducing pain and over-tightening.

A white respirator mask with a yellow safety face shield attached, featuring adjustable straps with gray and yellow markings.
A man wearing glasses and a white medical mask with an IV line attached, standing against a plain background.
A blue electronic fitness device with a screen displaying a message that reads 'Test Passed' and various fitness data. The device is on a blue surface, and part of a white and blue card or booklet is visible at the bottom.

NIOSH lab testing refined face-fit
geometry and prescription
eyewear integration.

A virtual reality headset with a camo-patterned faceplate, adjustable straps, and a clear visor.
A virtual reality headset with a clear visor and black strap, viewed from the side against a plain white background.
A female healthcare professional wearing scrubs and a face mask walking down a hospital corridor, with other healthcare workers in the background.

Built for first responders, scalable across military, industrial, and trades.

Impact

+25%

Audibility

75%

Lower Lifetime Filter Cost

2

Utility Patents

Close-up of a black wristwatch with yellow markers and a black strap, branded with the Tekla logo.
A black bike helmet with multiple ventilation holes and yellow accents, shown from the front against a dark background.
Close-up of the front of a white Land Rover Range Rover with the headlights on.
Close-up of a motocross rider wearing a Blue and Red Red Bull helmet with a tinted visor and red jersey.
N95 face mask with clear shield and yellow adjustable straps.
Crowd of people at an outdoor event, smiling and waving, with some holding flags and drinks, wearing casual clothing, sunglasses, and hats.
A dark blue flag with the IMT logo and the slogan 'Build the Future' flying against a clear blue sky.
Woman sitting cross-legged on a bed, reading a red book, with large windows and pillows in the background in a bright room.
Red Bull Tour Bus logo on a shiny surface with stage and lighting setup in the background.
A person wearing a black helmet and goggles is skiing through deep snow, causing a snow cloud around them.