Homemade reusable n100 mask by Big Bits Studio

Download the printable template here:

Because of the drastic spread of COVID-19, medical professionals are needing masks. However, the masks that we have been currently using are not full proof. Looking at the issue with n95 masks-

We decided to create a mask that you can make at home (and no, you don’t need toilet paper for this one). Here are the materials you’ll need:

Cardboard (from boxes such as fruit snacks and pancake mix… make sure it’s sturdy!)

Big Bits template (found at the top of this blog)

A straight edge

Masking tape

Plasti-Dip

Clear packing tape

Dish Gloves

4 Empty pudding cups

Silicone

A HEPA filter

Scissors

A pencil

String

To design the mask, Morgan used a free human scan from renderpeople.com and modeled a mask to fit using Maya to keep the polygon count low. This helps to accurately unfold the model into the cardboard.



Step 1: Cut out the cardboard using the template located at the top of the blog.

Cutting the cardboard

Step 2: Use Packing Tape to seal the inside of the mask.

We want the mask to be reusable which means we have to make it water-resistant. Coat the inside surface with clear packing tape.

Connect the points with a straight edge and score the cardboard with a blade so it could be easily folded.

Taping with packing tape

Step 3: Fold your mask as shown below and tape all seams with masking tape.



Folding the mask

Step 3: Trace out the HEPA filter with a pencil and the opening of the pudding cup.

Outline filter with cup to cut out

Step 4: Cut out the trace that you made along with a hole in the pudding cups.

The hole should outline the bottom of the cup

Step 5: Place the cut-out HEPA filter into the pudding cups evenly.

Start by putting the filter into one cup and then gently stack the other cup over the first one, creating a tight seal but leaving room for the filter.

You will do this again for the second set of pudding cups

Attaching filters to the cups

Step 6: Seal up any cracks with silicone.

Areas needed to be sealed are shown in the video (can be found at the bottom of the blog).

Sealing edges with silicone

Step 7: Attach the cup to the holes cut out in the mask with silicone.

Step 8: Coat the outside in Plasti-Dip or other spray-on rubber coating.

Ironically you need to be wearing an n100 mask when you spray Plasti-Dip.

This coating will not only make the surface impenetrable, but it will also make it water-resistant meaning the mask can be sterilized and reused. For a cheaper option just use packing tape to seal the outside.

Plasti-Dip Application

Step 9: Make a simple one-way valve to make exhaling easier and to help cut down on moisture build-up inside the mask.

This is an optional step and may or may not decrease the protective qualities of the mask. The valve is made of two layers of rubber.

The inside layer has a hole in the center and the outside layer is stretched tightly over the hole with a small gap in the tape to let the air out.



Step 10: Cut out dish gloves to form to the opening of the mask.

There are many types of dish gloves. It may be best to use a latex-free glove to prevent allergic reactions. The important thing here is to use a thick enough rubber that it seals the mask around your face.

Step 11: Use silicone again to seal the rubber gasket to the inner edge of the mask.

Make sure it’s a tight seal so no air gets in!

Gluing and cut piece of glove

Application of glove to mask

Step 12: Make a hole for your strap that is on the outside of your rubber seal with string.

And there you have it! One usable mask ready for action! By taking care to cut multiple parts from each material you should be able to make dozens of masks and reduce the price of each mask down to about $1.50.

If you have any improvements to this design, please leave them in the comments of the video!

Watch the how-to video on making an n100 respirator mask

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