This face mask tutorial is made due to a shortage of face masks at present. The face masks are temporary ones which are made with raw materials now available in the market and by modeling the design and the principle of 3M masks. The cost is low, and it is easy to learn and make. However, the face masks are certainly not as effective as N95 (KN95) masks. They are suitable for people who have no way to buy a face mask. The face masks are homemade and are not sterilized. They don’t meet uniform standard and are far from medical standard. Therefore, it’s not recommended for frontline medical personnel to use them. Please choose rationally.

Materials

Tools

  • Sealing machine or hand sewing, sewing machine
  • Flat clinch stapler, straight ruler, cutter, scissors
  • A piece of cardboard

I. Face Mask Structure

Fabric layer design

  • Layer 1: Spunbonded fabric (50-60g)
  • Layer 2: Meltblown fabric (50g)
  • Layer 3: Spunbonded fabric (50-60g)
  • Total thickness: 150-170g/m²

N95 masks are mostly made from 50g meltblown fabric. Most meltblown fabrics available in the market are 25g ones. So it is recommended to use two-layer 25g or single layer 50g meltblown fabric to make a N95 (stereoscopic) mask.

Plan Analysis

  • Outermost layer (layer 1): Its main functions include water and droplet protection as well as acting as the support for the whole mask. PP spunbonded fabric is used. Fabric thickness is proportioned based on the thickness of the core layer (please go to the end of the article for more details). Key word: spunbonded fabric
  • Core layer (layer 2): As the key part of the face masks, the meltblown nonwoven fabric with static charge after electret processing must be used to capture germs and particles by electrostatic attraction. The filter efficacy of qualified meltblown fabrics is over 95% while that of the ones without electret processing is only 20-35%. Key word: meltblown nonwoven fabric with static charge
  • Innermost layer (layer 3): The condensation of the exhaled breath will cause static decay until complete efficacy loss. There must be a waterproof layer between mouth and nose and the meltblown nonwoven fabric to reduce static loss. Key word: spunbonded fabric

II. Steps

Make a paper pattern. Get a piece of cardboard and cut it into a rectangle of 4.92 in x 4.72 in(12.5 cm x 12 cm). Refer to the picture below to draw lines and then cut the cardboard. The paper pattern can be reused to speed up production.

Cut the spunbonded fabric and the meltblown fabric into the pieces of 25*12.5cm.

Place the prepared fabrics according to the fabric layer design.

Double the placed fabrics. Put the paper pattern on the fabrics, draw a line by tracing the edge of the paper pattern and cut the fabrics. The fabrics after doubling may be too thick to cut, so there might be a size error after cutting. To avoid it, the cutting can be achieved in steps.

Unfold the fabrics, put them in order, and then seal the edge. A sealing machine can be used. If you are good at sewing, you can also sew it.

Edge sealing shall be carried out on two sides and in several times. Seal the single side (the red line). Then double the fabrics and seal two sides together (the blue line). Finally, trim the edges slightly with scissors to make it more beautiful and tidier. The main body of the face mask is finished.

Fix the nose strip to the mask with double sided adhesive tape. Fix the elastic cord with a flat clinch stapler. Raised staple will hurt your face, do not use it. When fixing the cord, its end shall be rear-facing to form reverse tension to avoid cord escape.

Done!