Making face masks
We're currently experimenting with ways to produce a lot of effective face masks. We've learned a few things and found some good resources so far.
Maker Mask has a good overview of material options: https://makermask.org/the-big-four-criteria-for-community-mask-materials/
3D printer heat sealing
We're experimenting with automated alternatives to sewing, using a 3D printer's hotend to melt seams into masks. We've found a lowish temperature (160-180C) and a slow print speed (10-20mm/s) work well for melting spunbond polypropylene fabric together. Careful bed leveling and Z zeroing are essential for this method to work properly, and there is a chance you'll need to calibrate a z-offset using M206 or your slicing software. To make the pattern you can simply draw it in Inkscape, make sure the pattern is a solid shape (might need to union or stroke to path in some cases), and turn it into a 3D model using Tinkercad or something similar. Then slice as normal, optionally using 0% infill depending on your design. For fixing the material to the bed we use blue painter's tape.
Easy mask designs
For a simple multi-layered cloth mask option, we've found this technique is easy and seals well over the mouth and nose: https://youtu.be/lOe_8z8k01U
This one has a few more variations on that idea: https://youtu.be/ieI7HITRm3c
And this one uses some fabric glue to keep it from falling apart when you take it off: https://youtu.be/ha6xEjnXO34
There are also lots of options for 3D printed clips that you can attach to hold your mask material: https://www.thingiverse.com/search?q=mask+clip
For earsaving hooks, the hospital here specifically requested this design which prints quickly and has three size options: https://www.thingiverse.com/thing:4261843