Design Reality

Creating the worlds first in mask quantitative fit check device

FitCheck® Technology

Respiratory Technology Limited

Respirators are worn in environments where hazardous airborne particles and gases are present, users are required to perform a fit check before every use- however existing fit check procedures are incredibly subjective putting users lives at risk.

FitCheck® Technology removes any ambiguity from the process, providing a quantitative check of respirator fit that can be performed by the user each time a respirator is worn.

The problem

Respiratory Technology Limited, approached Design Reality with a clear problem; due to the subjectivity of the testing process, mask wearers were passing daily fit checks when their masks were not fully sealed.  Our brief was to create a product design utilising sensor technology which could identify leaks within tight fitting respiratory protection, without hindering the performance of the mask in any way.


With twenty years of experience within the respiratory protection and PPE design, we had a sound knowledge of RPE within the marketplace.  This helps us to understand the best places to position test devices to maintain maximum user satisfaction and ease of testing.

Sensor technology

Our electronics team created sensor technology which could identify a drop in the pressure within the mask during a standard fit check procedure.  A loss caused by something as small as a hair under the seal could now be identified to the user.

A green light indicates an adequate seal has been made whilst a red light indicates a seal breach.

Award winning product design

FitCheck® Technology has been awarded the Red Dot Award for Product Design 2020


With an increased demand for Health and Safety monitoring, we created an app to integrated with FitCheck® Technology.  This means that users and employers can store and review the results, enabling them to demonstrate ongoing health and safety compliance.

Our team created the app, utilising UX experience and secured a listing on both Android and Apple platforms for the client.

Industrial Design

The product design team created a range of devices, designed to fit varying respirators, including an in-mask or on-filter variant to suit a full range of environments and businesses.

Testing and Certification

As part of our consultancy services we ensured the product was fully tested and certified.  FitCheck has completed EMC, radio and safety testing and is CE certified.


As part of the project we created visual brand guidelines, in addition to trademark registration for the logo.  We have also guided the client through the IP process.

Future product development

Respiratory Technology Limited wanted to ensure they had a clear vision of future product development; we have supported them to ensure that the next phase of product releases are in planning.





Sensor Technology

Industrial Design