I have made many of these masks for friends and family then created these files to share a digital version more easily.
These two designs are complete with instructions for personal use. I hope they can help you stay safe. I'd love to see a photo if you decide to make one!
I ended up in a full iterative design process with research for requirements and creating iterative real-world prototypes to test functionality and comfort.
The experts said that "a mask that is worn is better than an air tight one that stays back home." These masks passed the basic home fit tests for non-medical use better than any pattern I found online.
This first mask is a stylish yet comfortable mask with a pocket for a filter. This style takes a bit more effort to make because it fits nicely under the chin which I hope makes it a bit harder for nasty particles to sneak in.
In both designs, I mapped a face inside the pattern to get plenty of space for noses of all sizes.
Mask Front with Wire Casing
Chin Cover and Lining
Lining with Filter Pocket
Filter Pattern to help block small particles
Instructions Page 1
Instructions Page 2
Instructions Page 3
This Mask is a simpler design that has a pocket to easily add a custom HEPA vacuum bag filter. I found an obscure published study showing that anyone can improve the filtering capability of any mask or filter material simply by dipping it in salt water and letting it dry before using. A salted virus loses its will to infect.
One unique feature is the "Wire Casing" I designed after breaking a sewing machine needle on the metal wire. I've not seen this done anywhere and it greatly simplifies the trickiest part of sewing Covid-19 masks. It also allows easy access for replacement if the wire breaks for enthusiastic bending.
Although not a part of these designs, I used Autodesk Fusion 360 to create hardware for adjustable elastic straps adjustable for the masks I mailed across the country to insure a good fit.
Mask Front
Lining and Filter Pocket
Filter Pattern
Instructions Page 1
