Custom-fit reusable respiratory protective device

A method of fabricating a respiratory protective device, the method comprising:

• acquiring (i) a set of images or scans of a user or (ii) a scanned facial profile of the user;
• generating, by a processor, a model of the facial profile of a facial region of the user based on (i) the set of images or scans of the user or (ii) the scanned facial profile of the user;
• determining, by the processor, (i) a plurality of anatomical facial landmarks, including at least an infraorbitale and a zygomatic, and (ii) a plurality of mathematically determined landmarks derived from the plurality of anatomical facial landmarks, including a face side point, a jaw side point, and a jaw point, wherein the plurality of mathematically determined landmarks are derived by projecting the plurality of anatomical facial landmarks onto 2D planes to determine intermediate process landmarks;
• determining, by the processor executing a taxonomy model, using the determined plurality of anatomical facial landmarks and the plurality of mathematically determined landmarks derived therefrom, at least one of a frame or a contour thereof that can be fit-ably placed on the user that extends over both upper-cheek regions of the user, over both mid-cheek position regions of the user, and a chin region of the user, wherein the frame matches the taxonomy model and has facial landmarks identified on the face of the user in the scanned facial profile,
• wherein the at least one of the frame or the contour thereof is employed in one or more manufacturing operations to manufacture or fabricate the frame having the contour that maintains a breathable filter covering over the facial region of the user.