Protective efficiency of filtering dust respirators depends on the properties of filter materials from which filters are made and the structure of a half mask frame, which influences how tightly the respirator fits the face. The conducted studies on the "Lepestok 40" dust respirator revealed a large air leakage through the gaps occurring along the obturation strip. Therefore, the purpose of the study is to develop a dust respirator to provide high level of protection and usability by improving the half mask frame design. A scheme for designing a dust respirator: analysis of operating conditions for the dust respirator; facial anthropometric measurements of potential users; designing a 3D model of half mask frame; laboratory testing of the protective properties of the product. A distinctive feature of this approach is considering the facial anthropometric dimensions of employees of a particular enterprise, standard sizes formation of 3D facial models, which is the basis for designing a half mask frame for dust respirator. A new half mask frame design for dust respirator with a variable geometry of fitting to the face surface has been developed, due to special attachment points that allow changing its size according to the anthropometric dimensions of user's face.