Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated facial mask fabrication system that is capable of fabricating facial mask in an automated manner thereby reducing the physical efforts of the user.

BACKGROUND OF THE INVENTION

[0002] Facial mask fabrication is crucial for both aesthetic and therapeutic purposes, as it enables the creation of tailored delivery systems such as sheets, clays, and gels designed to maximize the absorption of active ingredients into the skin. By ensuring precise adherence and providing an enclosed, occlusive environment, these specialized products effectively deliver concentrated treatments, including hydration, anti-aging nutrients, and sebum control, while simultaneously deep-cleansing pores. Beyond immediate cosmetic improvements in skin radiance and texture, the manufacturing of masks, particularly with advanced materials like hydrogel or bio-cellulose, offers targeted solutions for dermatological conditions such as inflammation and acne. Furthermore, custom-fabricated pressure masks serve a critical medical function by facilitating scar maturation, flattening hypertrophic scars, and enhancing healing after facial surgery.

[0003] Conventional methods of facial mask fabrication involve formulating, coating, and cutting, often starting with the creation of a gel or emulsion containing active ingredients, polymers like polyvinyl alcohol (PVA), and thickeners to ensure proper viscosity and adhesion. Peel-off masks are created by formulating a suspension that dries into a removable film, while rinse-off types utilize clays like kaolin or bentonite to form a thick, absorbent layer. In contrast, popular sheet masks are manufactured by soaking substrates, such as non-woven fabrics or cotton, in a serum, followed by cutting them into specific shapes and packing them, using high-speed, automated assembly lines that incorporate ultrasonic welding to ensure consistent quality. For specialized needs, such as scar treatment, traditional fabrication involves molding a patient’s face with plaster to create a positive mold, over which thermoplastic or silicone materials are formed.

[0004] US20140318565A1 discloses a cosmetic facial mask is described, having high fitting properties onto skin, an excellent skin tightening effect, and an excellent lift-up effect on a flaccid cheek or face line. The cosmetic facial mask includes a laminate in which a non-elastomeric fiber layer and an elastomer layer are integrated through lamination, and has stretchability in a vertical direction of a face.

[0005] US20150250971A1 discloses masks for various uses and methods for manufacture thereof, including masks for use in continuous positive air pressure (CPAP) therapies. An example includes a mask having a first, relatively softer material for contact with the face of the user, and a second, relatively harder or more structural material used away from the face of the user, with a gradient there between. The mask can be produced by additive manufacturing to avoid a discernible boundary between the first and second materials.

[0006] Conventionally, many systems are available which are used to fabricate facial mask. However, these systems do not measure dimensions and facial contours of the user for fabricating the facial mask depending on the measured dimensions and also lacks in detecting an accumulated waste load during fabrication of the facial mask for alerts the user to manage the waste accumulation.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that is used to fabricate facial masks by measuring dimensions and facial contours of the user for fabricating the facial mask depending on the measured dimensions and also detecting the accumulated waste load during fabrication of the facial mask for alerts the user to manage the waste accumulation.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a system that is capable of fabricating facial mask in an automated manner thereby reducing the physical efforts of the user.

[0010] Another object of the present invention is to develop a system that is capable of measuring dimensions and facial contours of the user and thereby fabricates the facial mask depending on the measured dimensions.

[0011] Yet another object of the present invention is to develop a system that is capable of detecting accumulated waste load during fabrication of the facial mask and thereby alerts the user for managing the waste accumulation.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to an automated facial mask fabrication system that is capable of fabricating facial mask by measuring dimensions and facial contours of the user and thereby fabricates the facial mask depending on the measured dimensions.

[0014] According to an embodiment of the present invention, an automated facial mask fabrication system, comprising, a housing paired with a user interaction module for receiving input commands to fabricate a reinforced facial mask, the user interaction module includes but is not limited to a touch interactive display panel, a microphone, a user interface installed in a wirelessly connected computing unit for providing commands and a speaker for providing audible alerts, a multi-sectioned storage unit disposed within the housing, comprising a first compartment for storing aluminum sheets, a second compartment for storing straps, a third compartment for storing basalt fiber fabric sheets, each compartment being equipped with a lweight sensor for inventory monitoring, a handling module comprising a two-axis motorized slider assembled onto an inner wall of the housing, and equipped with multiple clamping units configured to access the stored aluminum sheet, strap and the fabric sheets from the respective compartments of the multi-sectioned storage unit to position onto a central platform installed centrally within the housing adapted to serve a workspace to support fabrication operations, the clamping units comprises a pressure sensor configured to regulate gripping force during transfer and placement of materials from the multi-sectioned storage unit, a facial contour scanning module installed on the housing, comprising an adjustable circular frame attached with an extendable bar to secure and support a user’s face for enabling an integrated monitoring unit to measure dimensions and facial contours, the adjustable circular frame is transparent and comprises a plurality of hinge joints configured to dynamically reshape the frame to conform to diverse facial structures, in synchronization with the monitoring unit which includes a laser measurement sensor and an imaging camera that detects facial dimensions, eye size, inter-eye spacing and monitor facial contours, respectively, a laser cutting module arranged within the housing over the two-axis motorized slider, adapted to cut the aluminum sheet and the basalt fiber fabric sheet for forming a base layer and a reinforcement layer of a mask based on facial dimensions and contours captured by the facial contour scanning module, the laser cutting module is connected to the two-axis motorized slider via an articulated rod and further comprises, a laser cutter, an integrated camera module and an RPM (Revolution per minute) sensor configured to monitor and adjust cutting speed based on material requirements.

[0015] According to another embodiment of the present invention, the present invention further comprises of, a resin infusion assembly arranged within the housing, including a resin storage chamber, a heating element disposed in the storage chamber and a conduit extending from the storage chamber to a spraying nozzle positioned above the platform to dispose thermosetting resin in between the base layer and the reinforcement layers, the heating element comprises a nichrome heating wire positioned beneath the resin storage chamber to maintain fluid viscosity, a first temperature sensor embedded within the resin storage chamber and a flow sensor integrated into the conduit to monitor and regulate resin flow through the spraying nozzle, the thermosetting resin stored in the resin storage chamber comprises an eco-friendly, skin-compatible thermosetting resin matrix, a cooling unit installed in the housing, adapted to direct conditioned airflow onto the dispensed resin for curing of the fabricated face mask, the motorized cooling unit is mounted on a slider and connected via an articulated rod, synchronized with an embedded second temperature sensor configured to monitor cooling conditions and automatically adjust airflow intensity and direction, a control unit operatively coupled with the scanning module, configured to receive input commands from a wirelessly linked user interaction module, and analyze the dimensions and facial contours to generate a three-dimensional facial model for triggering the handling module, laser cutting module, the resin infusion assembly, and cooling unit to execute an automated mask fabrication sequence, a waste storage chamber configured to collect material remnants from cutting operations via a robotic arm, the waste storage chamber comprising an embedded load sensor configured to detect an accumulated waste load and alert a user when the chamber nears capacity, at least one gripping unit further attached to automatically position straps onto an inner side of a formed mask structure at ear regions after resin dispensing, the dispensed resin functioning as an adhesive to bond the straps to the mask.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of an automated facial mask fabrication system.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to an automated facial mask fabrication system that is capable of fabricating facial mask by detecting an accumulated waste load during fabrication of the facial mask and thereby alerts the user for managing the waste accumulation.

[0022] Referring to Figure 1, an isometric view of an automated facial mask fabrication system is illustrated, comprising, a housing 101 paired with a user interaction module includes but is not limited to a touch interactive display panel 102, a microphone 103, and a speaker 104, a multi-sectioned storage unit disposed within the housing 101 comprising a first compartment 105, a second compartment 106, a third compartment 107, a handling module comprising a two-axis motorized slider 108 assembled onto an inner wall of the housing 101 and equipped with multiple clamping units 109, a central platform 110 installed centrally within the housing 101, a facial contour scanning module installed on the housing 101, comprising an adjustable circular frame 111 attached with an extendable bar 112, the adjustable circular frame 111 is transparent and comprises a plurality of hinge joints 113 in synchronization with an imaging camera 114.

[0023] Referring to Figure 1, an isometric view of an automated facial mask fabrication system is illustrated, further comprising a laser cutting module arranged within the housing 101 over the two-axis motorized slider 108 via an extendable rod 124, and further comprises a laser cutter 125, a resin infusion assembly arranged within the housing 101, including a resin storage chamber 115, a heating element disposed in the storage chamber 115 and a conduit 117 extending from the storage chamber 115 to a spraying nozzle 118 positioned above the platform 110, the heating element disposed in the storage chamber 115 comprises a nichrome heating wire 116 positioned beneath the resin storage chamber 115, a cooling unit 119 installed in the housing 101, the motorized cooling unit 119 is mounted on a slider 120 and connected via an articulated rod 121, a waste storage chamber 122 configured, one gripping unit 123 further configured in the housing 101.

[0024] The system discloses herein comprises a housing 101 paired with a user interaction module for receiving input commands to fabricate a reinforced facial mask. The user interaction module includes but is not limited to a touch interactive display panel 102, a microphone 103, a user interface installed in a wirelessly connected computing unit for providing commands and a speaker 104 for providing audible alerts.

[0025] In an embodiment of the present invention, the user interaction module includes the touch interactive display panel 102. The touch interactive display panel 102 as mentioned herein is typically an LCD (Liquid Crystal Display) screen that presents output in a visible form. The screen is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers. A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated when the user inputs details regarding fabricating a reinforced facial mask. A touch controller is typically connected to the microcontroller through various interfaces which may include but are not limited to SPI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit).

[0026] In another embodiment of the present invention, the user interaction module includes the microphone 103. The microphone 103 mentioned herein works as a transducer that converts sound waves into audio signal. The microphone 103 on receiving the input commands from the user converts the input signal into electrical signal and sends it to the microcontroller. The microcontroller processes the received signals in order to analyse the voice inputs of the user and upon analysing the voice commands the microcontroller actuates the microphone and accordingly commands the system to receive input commands to fabricate the reinforced facial mask.

[0027] In another embodiment of the present invention, the user interaction module includes the speaker 104. The speaker 104 consists of audio information, which is in the form of recorded voice, synthesized voice, or other sounds, generated or stored as digital data. The digital audio data is converted into analog electrical signals. Further the analog signal is amplified by an amplifier and the amplified audio signal is then sent to the speaker 104. The core of the speaker 104 is an electromagnet attached to a flexible cone. These sound waves travel through the air as pressure waves and are picked by the user’s ear. The speaker 104 is connected to the microcontroller, the microcontroller activates the speaker 104 forproviding audible alerts.

[0028] Herein, the user interface installed in a wirelessly connected computing unit to receive input commands to fabricate the reinforced facial mask. The computing unit includes but not limited to a mobile and laptop that comprises a processor where the input received from the user is stored to process and retrieve the output data in order to display in the computing unit. The microcontroller is wirelessly linked with the computing unit via a communication module which includes but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module. GSM (Global System for Mobile communication). The communication module acts as a medium between various electronic unit for establishing communication between the computing unit and system to process the input given by the user.

[0029] The GSM works by functioning as a miniaturized mobile station, utilizing an inserted SIM card to authenticate and connect to a 2G cellular network provider via radio transceivers. The GSM communicates with the microcontroller through serial communication (UART) using standardized AT commands, which allow the host to send instructions to dial, receive calls, or send/receive SMS messages. When transmitting data, the module converts the digital data from the microcontroller into radio waves and sends them to the nearest base station, while incoming radio signals are received by the antenna, processed, and demodulated into readable serial data. The onboard antenna and specialized chipset ensure bidirectional wireless communication, bridging the gap and the global cellular infrastructure.

[0030] Herein, a multi-sectioned storage unit positioned within the housing 101, the multi-sectioned storage unit comprises a first compartment 105 for storing aluminum sheets, a second compartment 106 for storing straps, a third compartment 107 for storing basalt fiber fabric sheets, each compartment being equipped with a weight sensor activated by microcontroller for inventory monitoring. The weight sensor comprises of a convoluted diaphragm and a sensing module. Due to the weight of inventory in the multi-sectioned storage unit, the size of the diaphragm changes which is detected by the sensing module. The sensing module detects the inventory weight and on the basis of the changes in sizes of the diaphragm, the acquired data is forwarded to the microcontroller in the form of a signal for further processing thereby monitoring the weight of the inventory.

[0031] Further, a handling module comprising a two-axis motorized slider 108 actuated by microcontroller assembled onto an inner wall of the housing 101 and equipped with multiple clamping units 109 actuated by microcontroller attached to access the stored aluminum sheet, strap and the fabric sheets from the respective compartments of the multi-sectioned storage unit to position onto a central platform 110 mapped centrally within the housing 101 adapted to serve a workspace to support fabrication operations.

[0032] The two axis slider provide movement in two axes simultaneously. The two-axis slider sliders are designed to control both horizontal (side-to-side) and vertical (up-and-down) movement of clamping unit 109. The motorized two-axis sliders use electric motors and precise gear arrangement to control the movement of the clamping unit 109. The two-axis slider comprises of a pair of sliding rail assembled perpendicular to each other and on actuation the gear mechanism translates the clamping unit 109 thereby positioning of the clamping unit 109.

[0033] The clamping unit 109 used herein has an open side and a curved side, forming a partial circle or a half-moon shape. At the open side of the clamping unit 109, there is a screw arrangement which includes a threaded screw or spindle and an electric motor. As the motor rotates it causes the screw to move in or out, which in turn adjusts the width of the clamp opening and eventually applies the required force to access the stored aluminum sheet, strap and the fabric sheets from the respective compartments of the multi-sectioned storage unit to position onto the central platform 110 adapted to serve the workspace to support fabrication operations.

[0034] Herein, the clamping units 109 comprises a pressure sensor activated by microcontroller attached with each clamping unit 109 to detect gripping force during transfer and placement of materials from the multi-sectioned storage unit where the microcontroller regulates the gripping force in case detected force exceeds or recedes a threshold limit. The pressure sensor disclosed herein includes a sensing element that is the core component that directly interacts with the pressure being measured. It typically consists of a diaphragm or a membrane that deforms under the applied pressure. When pressure is applied to the sensing element, it causes a diaphragm present within the sensor to flex or deform. The amount of deformation is proportional to the applied pressure. The deformation of the sensing element is converted into a measurable electrical signal which is processed by the microcontroller to detect gripping force during transfer and placement of materials from the multi-sectioned storage unit, where the microcontroller regulates the gripping force in case detected force exceeds or recedes a threshold limit.

[0035] Further, a facial contour scanning module mapped on the housing 101, the facial contour scanning module comprises an adjustable circular frame 111 attached with an extendable bar 112 actuated by microcontroller to secure and support a user’s face for enabling an integrated monitoring unit to measure dimensions and facial contours. The monitoring unit includes an artificial intelligence-based imaging camera 114 and a laser measurement sensor.

[0036] The extendable bar 112 operates using pneumatic unit including an air compressor, air cylinders, air valves and piston which works in collaboration to aid in extension and retraction of the bar 112. The pneumatic unit is operated by the microcontroller, such that the microcontroller actuates valve to allow passage of compressed air from the compressor within the cylinder, the compressed air further develops pressure against the piston and results in pushing and extending the piston. The piston is connected with the bar 112 and due to applied pressure, the bar 112 extends and similarly, the microcontroller retracts the bar 112 by closing the valve resulting in retraction of the piston. Thus, the microcontroller regulates the extension/retraction of the bar 112 to position the adjustable circular frame 111 thereby securing and supporting the user’s face for enabling an integrated monitoring unit to measure dimensions and facial contours.

[0037] Further, the adjustable circular frame 111 is transparent and comprises multiple hinge joints 113 actuated by microcontroller attached to dynamically reshape the frame 111 to conform to diverse facial structures. The hinge joint 113 mentioned above is preferably a motorized hinge joint 113 that involves the use of an electric motor to control the movement of the hinge and the adjustable circular frame 111. The hinge joint 113 provides the pivot point around which the movement occurs. The motor is the core component responsible for generating the rotational motion. It converts the electrical energy into mechanical energy, producing the necessary torque that drives the hinge joint 113. As the motor rotates, the motorized hinge joint 113 tilts to dynamically reshape the frame 111 to conform to diverse facial structures, in synchronization with the monitoring unit which includes a laser measurement sensor and an imaging camera 114 activated by microcontroller that detects facial dimensions, eye size, inter-eye spacing and monitor facial contours, respectively.

[0038] The laser measurement sensor emits a laser beam which is usually in the form of a focused, collimated light beam that hits the face, it gets reflected back towards the sensors. The time it takes for the laser beam to travel from the sensor to the ground and back is measured. The sensor precisely measures the time it takes for the laser beam to travel to the face surface and return. Using the speed of light as a constant the sensor calculates the distance between itself and the face surface. The laser measurement sensor collects a significant amount of data by scanning the entire surface of the face and forms a 3D point cloud, which represents the shape of the face. The laser measurement sensor sends the data to a microcontroller which processes the acquired data and detects the facial dimensions, eye size, inter-eye spacing and monitor facial contours, respectively.

[0039] The imaging camera 114 comprises of an image capturing arrangement including a set of lenses that captures multiple images of the face, and the captured images are stored within memory of the imaging unit in form of an optical data. The imaging camera 114 also comprises of a processor that is integrated with artificial intelligence protocols, such that the processor processes the optical data and extracts the required data from the captured images. The extracted data is further converted into digital pulses and bits and are further transmitted to the microcontroller. The microcontroller processes the received data and determines facial dimensions, eye size, inter-eye spacing and monitor facial contours, respectively.

[0040] Further, a laser cutting module positioned within the housing 101 over the two-axis motorized slider 108 adapted to cut the aluminum sheet and the basalt fiber fabric sheet for forming a base layer and a reinforcement layer of a mask based on facial dimensions and contours captured by the facial contour scanning module. The laser cutting module is connected to the two-axis motorized slider 108 via an extendable rod 124 and further comprises a laser cutter 125, an integrated camera module and an RPM (Revolution per minute) sensor activated by microcontroller attached to monitor and adjust cutting speed based on material requirements. The two-axis slider 108 are designed to control both horizontal (side-to-side) and vertical (up-and-down) movement of laser cutting module. The motorized two-axis slider 108 use electric motors and precise gear arrangement to control the movement of the laser cutting module.

[0041] The two-axis slider 108 comprises of a pair of sliding rail assembled perpendicular to each other and on actuation the gear arrangement translates the laser cutting module. The two-axis motorized slider 108 typically an XY gantry move the laser head across the housing 101 with high positioning accuracy. During the process, the laser first cuts through an aluminum sheet using fusion cutting often assisted by an inert gas jet like nitrogen to blow away molten metal to form a rigid base layer. It then processes the basalt fiber fabric sheet, often via vaporization to ensure clean, fiber-seal edges, creating a reinforcement layer that precisely matches the captured facial dimensions and contours.

[0042] The laser cutting module operates as a dynamic component is linked to the two-axis motorized slider 108 by an extendable rod 124 that allows for precise height and reach adjustments. The laser cutting module utilizes a laser cutter 125 and an integrated camera module to visually guide the cutting process, while an RPM sensor continuously tracks mechanical performance. These components are synchronized by the microcontroller, which processes real-time data to automatically monitor and modulate the cutting speed based on the specific resistance and thickness of the material being processed.

[0043] The extendable rod 124 operates on pneumatic unit including an air compressor, air cylinders, air valves and piston which works in collaboration to aid in extension and retraction of the rod 124. The pneumatic unit is operated by the microcontroller, such that the microcontroller actuates valve to allow passage of compressed air from the compressor within the cylinder, the compressed air further develops pressure against the piston and results in pushing and extending the piston. The piston is connected with the rod 124 and due to applied pressure, the rod 124 extends and similarly, the microcontroller retracts the extendable rod 124 by closing the valve resulting in retraction of the piston. Thus, the microcontroller regulates the extension/retraction of the rod 124 in order to position the laser cutter 125.

[0044] The integrated camera module and the RPM sensor work together to optimize cutting speeds for different materials. The camera module, typically a CCD or CMOS sensor, captures real-time visual data of the cutting zone, identifying material type or edge quality, which is transmitted to the microcontroller for processing. Simultaneously, the RPM sensor (tachometer) monitors the cutting speed of the laser cutter by measuring pulses from a rotating encoder disc, sending this speed data to the microcontroller. The microcontroller, pre-programmed with material-specific parameters, analyses the visual input and RPM data if the material requires a lower or higher cutting speed, it calculates the necessary correction and adjusts the speed by controlling the motor's power via Pulse Width Modulation (PWM) or a driver. This continuous monitoring and feedback loop ensure optimal cutting speed for the material, reducing tool wear and improving precision.

[0045] Herein, a waste storage chamber attached to collect material remnants from cutting operations via a robotic arm, the waste storage chamber comprising an embedded load sensor activated by microcontroller attached to detect an accumulated waste load and alert a user when the chamber nears capacity. The robotic arm used herein mainly comprises of motor controllers, arm, end effector and sensors. The arm is the essential part of the robotic arm and it comprises of three parts the shoulder, elbow and wrist. All these components are connected through joints, with the shoulder resting at the base of the arm, typically connected to the microcontroller. The elbow is in the middle and allows the upper section of the arm to move forward or backward independently of the lower section. Finally, the wrist is at the very end of the upper arm and attaches to the end effector. The end effector connected to the arm acts as a hand and acquire a grip of the surface for collecting material remnants from cutting operations.

[0046] The load sensor detects accumulated waste by converting the downward gravitational force (load) of the accumulated garbage into a proportionate electrical signal. As waste is added, the metal structure of the load cell undergoes minor deformation, causing the electrical resistance of the strain gauges bonded to it to change. This change in resistance creates a varying voltage output in a Wheatstone bridge circuit, which is subsequently processed and sent to the microcontroller to calculate the current weight of the waste load thereby detecting the accumulated waste load and alert the user when the chamber nears capacity.

[0047] Further, a resin infusion assembly positioned within the housing 101, including a resin storage chamber 115, a heating element mapped in the storage chamber 115 and a conduit 117 extending from the storage chamber 115 to a spraying nozzle 118 activated by microcontroller positioned above the platform 110 to dispose thermosetting resin in between the base layer and the reinforcement layers, the thermosetting resin stored in the resin storage chamber 115 comprises an eco-friendly, skin-compatible thermosetting resin matrix. The spraying nozzle 118 works by utilizing electrical energy to atomize the thermosetting resin in a controlled flow pattern by converting the pressure energy of the thermosetting resin into kinetic energy, which increases the thermosetting resin velocity. Upon actuation of nozzle 118 by the microcontroller, the electric motor or the pump pressurizes the incoming thermosetting resin, increasing its pressure significantly thereby disposing thermosetting resin in between the base layer and the reinforcement layers.

[0048] Herein, the heating element comprises a nichrome heating wire 116 positioned beneath the resin storage chamber 115 to maintain fluid viscosity, a first temperature sensor embedded within the resin storage chamber 115 to monitor resin temperature, and a flow sensor integrated into the conduit 117 to monitor and regulate resin flow through the spraying nozzle 118. The nichrome heating element, typically positioned beneath the resin storage chamber 115, works by utilizing the principle of Joule heating, where an electrical current passes through the high-resistance Nickel-Chromium alloy wire 116, causing it to generate uniform heat. This heat is conducted upward through the floor of the container to the resin, reducing its viscosity and increasing its flowability.

[0049] The first temperature sensor disclosed herein is equipped with two electrodes utilized to detect the rise in voltage across the electrodes due to heating of the surroundings. The detecting voltage is equivalent to the temperature that is sensed by the sensor. After then the sensor converts that detected temperature into electric signals and transmits that signal into the microcontroller. After that the microcontroller processes and analyze the signal to monitor resin temperature.

[0050] The flow sensor integrated into the conduit 117 to monitor and regulate resin flow through the spraying nozzle 118. The flow sensor works based on the principle of measuring the rate of resin flow. It typically consists of a sensing element, such as a turbine or a paddle wheel that is placed in the path of the resin. As the resin flows, it imparts a force or rotational motion on the sensing element, which is then converted into an electrical signal proportional to the flow rate. This signal is further processed by the microcontroller to monitor and regulate resin flow through the spraying nozzle 118.

[0051] Herein, a cooling unit 119 that is mapped in the housing 101, adapted to direct conditioned airflow onto the dispensed resin for curing of the fabricated face mask. The motorized cooling unit 119 is mounted on a slider 120 actuated by microcontroller and connected via an articulated rod 121, synchronized with an embedded second temperature sensor activated by microcontroller to monitor cooling conditions and automatically adjust airflow intensity and direction. The slider 120 consists of a pair of sliding rail fabricated with grooves in which the wheel of a slider 120 is positioned that is further connected with a bi-directional motor via a shaft. The microcontroller actuates the bi-directional motor to rotate in clockwise and anti-clockwise direction that aids in rotation of shaft, wherein the shaft converts the electrical energy into rotational energy for allowing movement of the wheel to translate over the sliding rail by a firm grip on the grooves. The movement of the slider 120 results in translation of the motorized cooling unit 119.

[0052] The motorized cooling unit 119 automatically adjusts airflow intensity and direction by utilizing onboard sensors such as temperature, humidity, or motion sensors to monitor environmental conditions and occupancy in real-time. These sensors send data to the microcontroller, to determine the required cooling needs. To control intensity, the microcontroller modulates a variable-speed motor (BLDC) to adjust blower RPM, increasing speed for rapid cooling thereby automatically adjust airflow intensity and direction.

[0053] Further, at least one gripping unit 123 further attached to automatically position straps onto an inner side of a formed mask structure at ear regions after resin dispensing, the dispensed resin functioning as an adhesive to bond the straps to the mask. The gripping unit 123 that is designed to position straps onto the inner side of the formed mask structure at ear regions after resin dispensing. The gripper typically incorporates a motorized arrangement that controls the opening and closing of the jaws of the gripper. The motor generates the necessary force to move the gripper’s fingers for the opening and closing of the jaws with precision. This motorized action is often controlled by the microcontroller for the smooth and precise gripping and positioning of the straps onto an inner side of the formed mask structure at ear regions after resin dispensing, the dispensed resin functioning as the adhesive to bond the straps to the mask.

[0054] Herein, a control unit operatively coupled with the scanning module, attached to receive input commands from a wirelessly linked user interaction module and analyze the dimensions and facial contours to generate a three-dimensional facial model for triggering the handling module, laser cutting module, the resin infusion assembly, and cooling unit 119 to execute an automated mask fabrication sequence. The control unit operating by first receiving, via a wireless module high-resolution point cloud data or RGB-D imagery of the user's face captured by a smartphone scanner. The control unit processes this input to analyse facial contours and dimensions, automatically generating a bespoke three-dimensional facial mesh and corresponding mask mold design. Upon finalizing the control unit transmits digital instructions to initiate a sense, think, act workflow it triggers the handling module to position raw material, activates the laser cutting module to trim the material to the precise 3D-molded contour, initiates the resin infusion assembly to seal the mask body, and finally manages the cooling unit 119 to cure the material, resulting in a customized, tightly fitted mask tailored to the user's facial model.

[0055] Lastly, a battery converts stored chemical energy into electricity through electrochemical reactions, the anode undergoes oxidation, releasing electrons that flow through the external circuit, while ions move through the electrolyte to the cathode to maintain charge balance. Integrated circuitry ensures regulated voltage and current, delivering consistent and safe energy to all components, supporting mobility, detection, and protective actions for continuous operation of automated facial mask fabrication.

[0056] The present invention works best in the following manner where, the housing 101 with the user interaction module for receiving input commands to fabricate the reinforced facial mask, the user interaction module includes but is not limited to the touch interactive display panel 102, the microphone 103, the user interface in the wirelessly connected computing unit and the speaker 104 for providing audible alerts. Herein, the multi-sectioned storage unit comprises the first compartment 105 for storing aluminum sheets, the second compartment 106 for storing straps, the third compartment 107 for storing basalt fiber fabric sheets, each compartment being equipped with the weight sensor for inventory monitoring. Further, the handling module comprising the two-axis motorized slider 108 and equipped with multiple clamping units 109 to access the stored aluminum sheet, strap and the fabric sheets from the respective compartments of the multi-sectioned storage unit to position onto the central platform 110 adapted to serve the workspace to support fabrication operations. Herein, the pressure sensor attached with each clamping units 109 to detect gripping force during transfer and placement of materials from the multi-sectioned storage unit where the microcontroller regulates the gripping force in case detected force exceeds or recedes the threshold limit. Further, the facial contour scanning module comprises the adjustable circular frame 111 with the extendable bar 112 to secure and support the user’s face for enabling the integrated monitoring unit to measure dimensions and facial contours of the user. Herein, the adjustable circular frame 111 is transparent and comprises multiple hinge joint 113 to dynamically reshape the frame 111 to conform to diverse facial structures in synchronization with the monitoring unit which includes laser measurement sensor and the imaging camera 114 that detects facial dimensions, eye size, inter-eye spacing and monitor facial contours, respectively. Further, the laser cutting module over the two-axis motorized slider 108 adapted to cut the aluminum sheet and the basalt fiber fabric sheet for forming the base layer and the reinforcement layer of the mask based on facial dimensions and contours captured by the facial contour scanning module. The laser cutting module with the two-axis motorized slider 108 via the extendable rod 124 and further comprises the integrated camera module and the RPM (Revolution per minute) sensor to monitor and adjust cutting speed based on material requirements.

[0057] In continuation, the waste storage chamber to collect material remnants from cutting operations via the robotic arm, comprising the embedded load sensor to detect the accumulated waste load and alert the user when the chamber nears capacity. Further, the resin infusion assembly including the resin storage chamber, the heating element mapped in the storage chamber and the conduit 117 extending from the storage chamber to the spraying nozzle 118 to dispose thermosetting resin in between the base layer and the reinforcement layers. Herein, the heating element comprises the nichrome heating wire 116 to maintain fluid viscosity, a first temperature sensor to monitor resin temperature, and a flow sensor to monitor and regulate resin flow through the spraying nozzle 118. Herein, the cooling unit 119 adapted to direct conditioned airflow onto the dispensed resin for curing of the fabricated face mask. The motorized cooling unit 119 and via the articulated rod 121, synchronized with the embedded second temperature sensor to monitor cooling conditions and automatically adjust airflow intensity and direction. Further, at least one gripping unit 123 to automatically position straps onto the inner side of the formed mask structure at ear regions after resin dispensing, the dispensed resin functioning as the adhesive to bond the straps to the mask. Herein, the control unit operatively coupled with the scanning module, to receive input commands from the wirelessly linked user interaction module and analyze the dimensions and facial contours to generate the three-dimensional facial model for triggering the handling module, laser cutting module, the resin infusion assembly, and cooling unit 119 to execute the automated mask fabrication sequence.

[0058] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) An automated facial mask fabrication system, comprising:
a) a housing 101 paired with a user interaction module for receiving input commands to fabricate a reinforced facial mask;
b) a multi-sectioned storage unit disposed within the housing 101, comprising a first compartment 105 for storing aluminum sheets, a second compartment 106 for storing straps, a third compartment 107 for storing basalt fiber fabric sheets, each compartment being equipped with a weight sensor for inventory monitoring;
c) a handling module comprising a two-axis motorized slider 108 assembled onto an inner wall of the housing 101, and equipped with a plurality of clamping units 109 configured to access the stored aluminum sheet, strap and the fabric sheets from the respective compartments of the multi-sectioned storage unit to position onto a central platform 110 installed centrally within the housing 101 adapted to serve a workspace to support fabrication operations;
d) a facial contour scanning module installed on the housing 101, comprising an adjustable circular frame 111 attached with an extendable bar 112 to secure and support a user’s face for enabling an integrated monitoring unit to measure dimensions and facial contours of the user;
e) a laser cutting module arranged within the housing 101 over the two-axis motorized slider 108, adapted to cut the aluminum sheet and the basalt fiber fabric sheet for forming a base layer and a reinforcement layer of a mask based on facial dimensions and contours captured by the facial contour scanning module;
f) a resin infusion assembly arranged within the housing 101, including a resin storage chamber, a heating element disposed in the storage chamber and a conduit 117 extending from the storage chamber to a spraying nozzle 118 positioned above the platform 110 to dispose thermosetting resin in between the base layer and the reinforcement layers;
g) a cooling unit 119 installed in the housing 101, adapted to direct conditioned airflow onto the dispensed resin for curing of the fabricated face mask; and
h) a control unit operatively coupled with the scanning module, configured to receive input commands from a wirelessly linked user interaction module, and analyze the dimensions and facial contours to generate a three-dimensional facial model for triggering the handling module, laser cutting module, the resin infusion assembly, and cooling unit 119 to execute an automated mask fabrication sequence.

2) The system as claimed in claim 1, wherein a pressure sensor integrated with each clamping unit 109 configured to detect gripping force during transfer and placement of materials from the multi-sectioned storage unit, where the microcontroller regulates the gripping force in case detected force exceeds or recedes a threshold limit.

3) The system as claimed in claim 1, wherein the adjustable circular frame 111 is transparent and comprises a plurality of hinge joints 113 configured to dynamically reshape the frame 111 to conform to diverse facial structures, in synchronization with the monitoring unit which includes a laser measurement sensor and an imaging camera 114 that detects facial dimensions, eye size, inter-eye spacing and monitor facial contours, respectively.

4) The system as claimed in claim 1, wherein the laser cutting module is connected to the two-axis motorized slider 108 via an extendable rod 124 and further comprises a laser cutter 125, an integrated camera module and an RPM (Revolution per minute) sensor configured to monitor and adjust cutting speed based on material requirements.

5) The system as claimed in claim 1, comprising a waste storage chamber configured to collect material remnants from cutting operations via a robotic arm installed in the housing, the waste storage chamber comprising an embedded load sensor configured to detect an accumulated waste load and alert a user when the chamber nears capacity.

6) The system as claimed in claim 1, wherein the heating element comprises a Nichrome heating wire 116 positioned beneath the resin storage chamber 115 to maintain fluid viscosity, a first temperature sensor embedded within the resin storage chamber 115 to monitor resin temperature, and a flow sensor integrated into the conduit 117 to monitor and regulate resin flow through the spraying nozzle 118.

7) The system as claimed in claim 1, wherein at least one gripping unit 123 further configured to automatically position straps onto an inner side of a formed mask structure at ear regions after resin dispensing, the dispensed resin functioning as an adhesive to bond the straps to the mask.

8) The system as claimed in claim 1, wherein the motorized cooling unit 119 is mounted on a slider 120 and connected via an articulated rod 121, synchronized with an embedded second temperature sensor configured to monitor cooling conditions and automatically adjust airflow intensity and direction.

9) The system as claimed in claim 1, wherein the user interaction module includes but is not limited to a touch interactive display panel 102, a microphone 103, a user interface installed in a wirelessly connected computing unit for providing commands and a speaker 104 for providing audible alerts.