I'm Actively making these for my local hospital, so this is a QUICK, down and dirty how-to. If I had any time at all to put into this how-to I'd probably make it with pretty fonts, a nice background, or maybe even a video. I don't, I need to crank out as many of these masks as I can for the hundreds of healthcare workers who don't have them.
You can find the files at the links below
YOU MUST PRINT THE GRID AT 98.5 PERCENT FOR IT AND THE FILTER MEDIA TO FIT INTO THE MASK CUP
Download the files and print them, 10% infill, PLA, no support. This is how I laid it out for a single complete mask on a finder, the smallest printer I own
Once printed, you need to add the filter media, foam, and strings and you're ready go to. I've made a how-to below.
For materials you will need the below items you can find at any home improvement center
- A MERV16 or FPR10 or better furnace filter. These can be found at any local hardware store. At home depot an FPR10, 24x24x1 filter costs about 20 bucks. The filter media is pleated which means its a sheet that is much larger than 24x24. This will yield well over 144 mask filter inserts.
2. You'll need weather stripping foam to seal the mask to the wearer's face. This is also found at home depot.
3. Elastic/Paracord/shoelace/ something to hold the mask on.
For assembly, first we need to get the filter material out of the filter housing. Remove the cardboard from the edges of the filter, this will leave you with just the filter material on a wire mesh. Carefully, remove the media from the wire mesh. This will leave you with the bare filter cloth.
Once you have the cloth free, place the cloth over the square opening on the inside of the mask, and , Install the mask grid inside the mask. It should just snap in
Now we need to add the foam. Line the outer edge of the mask with the foam. Make sure it sits outside of the mask, (as shown in the picture below) this will give it space to compress and contour to the shape of your face. When you get back to where you started, make sure the foam makes a tight seal against itself. This is a pressure activated adhesive so make sure you press nice and hard.
The test: To test that the foam is sealing ok, cover the vents on the front of the mask with your hand and see if you can breathe, if you can't you've done this step right. If you can, you'll need to find where the air is leaking in.
Now tie the elastics on it and you're ready to go. I will update these with paracord and a cord toggle shortly.