Reimagining face masks: reusable, self-sterilizing, and powered by electrostatics
About the Client
Card79 designed the Galvan Mask, part of the CDC/BARDA Mask Innovation Challenge, as a reusable and hygienic alternative to disposable surgical masks. The system includes a fabric mask and a self-cleaning case that recharges and sterilizes the mask with heat and static, maintaining filtration efficiency without waste
Project Brief
Create a mask and recharge system that preserves the electrostatic filtration properties of single-use masks. The design needed to wrap the mask in three electrostatic-capable layers and include a sleek case employing heat and oscillating metal to recharge the static and kill viruses.
Key Challenges
Maintaining electrostatic filtration across reuse Traditional masks lose electrostatic charge—essential to capturing aerosol particles—after only a few uses. The system had to recharge the mask each time to stay effective.
Integrating mask and hardware elegantly Designing two connected products—a mask and a sterilization case—without creating a disjointed user experience.
Balancing function and user trust Selecting materials like copper-infused antiviral textiles and multi-layer filtration fabrics while ensuring the mask feels comfortable, breathable, and sustainable.
Process
Material and layer selection Developed a three-layer mask: cotton-polyester for comfort and charge pickup; polypropylene as a rechargeable filter; hydrophobic polyester outer layer to inhibit moisture
Designing the sterilizing recharge system Engineered a reheating and oscillating-metal base inside the case to restore electrostatic charge and sanitize the mask.
Form and brand alignment Styled the mask and case to feel clean and efficient—reflecting Card79’s design ethos rather than industrial or homely appeal.
Packaging and interaction flow Designed a visual and physical pairing between mask and charging case that reinforces the mask-care ritual.
Solution
A reusable mask system that heals itself The Galvan Mask combines electrostatic filtration in the mask with a case that recharges and sanitizes—delivering ongoing performance without waste.
Designed for daily use and trust Material choices and layer architecture keep the mask breathable and comfortable, while copper and poly blends enhance safety and durability. The case feels intuitive and non-clinical.
Award-winning concept The Galvan Mask earned both the iF Design Award 2022 and the Good Design Award (Chicago Athenaeum) in 2021, in recognition of its thoughtful design and sustainable impact.
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