Making face masks

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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:

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:

This one has a few more variations on that idea:

And this one uses some fabric glue to keep it from falling apart when you take it off:

There are also lots of options for 3D printed clips that you can attach to hold your mask material:

For earsaving hooks, the hospital here specifically requested this design which prints quickly and has three size options: