Mask Instructions

The source of the information and initial design came from the University of Florida Health. We have slightly modified the design to use elastic straps as well as an updated shape for a better fit.

We are providing kits to volunteer sewists to help manufacture these masks. Each kit will provide enough material to make 20 masks. If you're interested in volunteering to sew, please see how in our FAQs page.

Click the button below to download a PDF copy of the Mask Instructions.

DOWNLOAD Mask Instructions PDF

PLEASE READ ALL INFORMATION ON THESE INSTRUCTIONS BEFORE MAKING MASKS

For any questions, contact us at: 5000maskchallenge@gmail.com

PRACTICE:

Before using the provided blue medical fabric material, please practice on cloth first. The medical fabric material will provide better protection than cloth masks, so we want to reduce scrap as much as possible.

PROVIDED SUPPLIES:

This kit provides enough supplies to make 20 masks. Provided in this kit:

Qty. 40 Blue H600 Medical Fabric Cutouts (Two sheets per mask)
920 inches Black Elastic for mask straps (Cut two 23-inch straps per mask)
120 inches Red and white gauge wire (Cut one 6-inch piece of red and white wire for nose piece per mask)
1 bag Clear plastic bag to return finished masks

NEEDED SUPPLIES:

Required:

Scissors, ruler/yardstick
Sewing machine, thread, sewing clips/paper clips (DO NOT: use pins to avoid holes in the protective medical fabric)
Jewelry pliers or needle-nose pliers, wire cutters
Lighter

Nice to have:

Cutting mat, rotary cutter
Seam ripper

Safety Precautions

NOTE: The masks will be sterilized when they are delivered to the hospital.

Please do not volunteer to make masks if you have EVER been diagnosed with COVID-19 or you have been in contact with someone with the diagnosis.
Do not make masks if you have ANY cold or flu-like symptoms including headache, sore throat, fever, cough, sneezing. Our masks will be used by those in high-risk groups, and we don't want to spread any virus or bacteria including COVID-19.
Any new sewing tools or equipment should be wiped down with an alcohol-based sanitizing cloth or cleaner before you begin.
Immediately before sewing, make sure hands are washed with soap and water.
Place completed masks in the plastic bag provided

DO NOT:

Wash the blue medical fabric material
Iron the blue medical fabric material
Wet the blue medical fabric material
Use pins. Instead, please use paperclips, sewing clips or alternatives to pins
Write on the fabric
Use pieces of fabric that are ripped
Use a different design than the ones outlined in these instructions

Mask Directions

PLEASE FOLLOW ALL STEPS IN THE DIRECTIONS. THESE MASKS HAVE PASSED FIT TESTS FOR HOSPITALS SO THE DESIGN SHOULD NOT BE ALTERED

Please practice on cloth or other material first to limit scrap of the medical fabric

STEPS:

1) Cut two pieces of the provided blue medical fabric cutouts to the 7" x 8" (mask body) shape shown below. (see Figure 1 and note below before continuing)

The bright blue side will be the outer side of the mask and the dull blue (whiter) side will be the inside of the mask (see Figure 2)
Note: The outside layer will have more defined pattern markings and a darker blue color.
The 7-inch sides will be the width across the top and the bottom of the mask.
The 8-inch sides will be pleated. Three pleats will make the final mask 4″ deep.

Figure 1: Mask body cutout dimensions

Note: The blue fabric has been cut into squares that may or may not include the four 1" x 3" triangle cutouts. Please check the dimensions of the pattern and make any "clean-up" cuts to achieve the required shape with the above dimensions. Initial bulk cutting of the mask material may have varying sizes/shapes. If the material is undersized and cannot be resized as required, please do not use it and return with the masks.

Figure 2: Mask material outer side vs inside

2) Layer the 2 pieces of blue 7″ x 8″ medical fabric on top of each other with the dull blue (whiter) inside facing out, the bright blue sides (exterior) of the fabric will be touching.

3) Sew a 1/4″ - 3/8" seam on the 7″ sides. Backstitch and trim excess thread. See Figure 3.

Figure 3: 1/4" seam on 7" sides of mask (inside of mask material facing out)

4) Turn the mask right side out. Finger press and form shape along stitching. Use clips if needed to keep shape secure.

5) Sew a topstitch 1/4″ - 3/8" from both edges on the 7" side of the material. Backstitch and trim excess thread.

6) For the nose piece, cut the red and white wire into a 6" piece. Make a small loop on each end of the wire and press flat (see Figure 4 below). The loops should be facing the same way.

Figure 4: Nose Piece wire cut and loops made

7) Insert the prepared wire into the 1/4″ seam on one of the sides you top stitched. Center the wire. This is now the TOP of the mask. See Figure 5.

Figure 5: Insert prepared wire into the 1/4" seam

8) Mark 2″ down from the TOP edge of the mask on both sides. Make three accordion-style pleats along the 8″ side as follows: Make the 3 half-inch pleats starting at the 2″ mark and clip each pleat - see Figure 6 and Figure 7. Space the pleats one after the other and clip them to make the mask 4″ wide. Adjust the pleats accordingly. The pleats do not have to be perfect as long as the mask is 4 inches wide - see Figure 7. This is VERY important because if the mask is too short, it won't go under the chin in some cases, and if the mask is too long, it could leave too much of a gap on the side of the face. Do not change the number of pleats as the bottom pleat is especially important to the curvature of the mask under the chin. See image below.

Figure 6: First pleat made 2" from the top of the mask

Figure 7: Mask is 4" long after 3 pleats made

9) Sew the pleats down by sewing 1/4″ seam. Repeat on the other side. When finished, the pleats will all be going down. See Figure 8.

Figure 8: Dimensions and stitching of pleated mask body

10) Cut two pieces of black elastic 23" long - see Figure 9

Elastic should be relaxed (not stretched) when measured
Burn the edges of the elastic with a lighter to reduce fraying

Figure 9: Black elastics cut to 23"

11) Mark the center of the elastic and clip to the mask close to the top of the mask. Elastics should be attached to the side with the pleats going down. See Figure 10 and Figure 11.

12) Sew the black elastic to the mask body using a zig-zag stitch. Ensure to back stick at the beginning and end of the stitch. See Figure 11.

Figure 10: Elastic clipped to mask body

Figure 11: Final mask stitching to attach the elastic straps

13) Trim all loose thread.

14) Place the finished mask in the provided return bag and email us that you have masks ready!

Disclaimer:

The surgical mask information is provided as research information only and has not been tested for commercial use. The mask Information is provided with permission for the recipient to freely use, copy and modify without restriction, subject to an obligation on the recipient to recognize University of Florida Health (UF Health) as the source of the information and design depicted in this material. The design is bare bones and materials should be locally available at hospitals that sterilize equipment. This design is for an adult mask for anyone at a higher risk for coronavirus, exposure or concern thereof. The mask Information is experimental in nature and the safety or efficacy for use in humans has not been proven. It has been tested using the standard N95 fit test and can fit test pass most people. It should not be used without the wearer N95 fit testing before use. If reused it is advised to use one of the standard CDC N95 mask reuse protocols. The design, and masks built in accordance with the design, have not been approved by the FDA or NIOSH.

DISCLAIMER: THE MASK INFORMATION IS PROVIDED "AS-IS, WHERE-IS," WITHOUT REPRESENTATIONS, CONDITIONS OR WARRANTIES OF ANY KIND, WHETHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OR THAT THE USE OF THE MASK INFORMATION WILL NOT INFRINGE ANY PATENT, COPYRIGHT, TRADEMARK OR OTHER PROPRIETARY RIGHTS. THE RECIPIENT IS SOLELY RESPONSIBLE FOR DETERMINING THE APPROPRIATENESS OF USING, REPLICATING OR REDISTRIBUTING THE MASK INFORMATION AND DESIGN. IN THIS REGARD, THE RECIPIENT ASSUMES ALL LIABILITY FOR DAMAGES, OF WHATEVER NATURE AND DESCRIPTION, WHETHER IN CONTRACT OR IN TORT, WHICH MAY ARISE FROM THE USE OF THE MASK INFORMATION AND DESIGN. THE UNIVERSITY OF FLORIDA AND THE 5000MASKCHALLENGE, INCLUDING ITS EMPLOYEES AND AGENTS, WILL NOT BE LIABLE TO THE RECIPIENT OR TO ANY THIRD PARTY FOR ANY LOSS, CLAIM OR DEMAND MADE BY THE RECIPIENT, OR ANY LOSS, CLAIM, DEMAND OR JUDGMENT AGAINST THE RECIPIENT BY ANY OTHER PARTY, DUE TO OR ARISING FROM THE USE OF THE MASK INFORMATION AND DESIGN BY THE RECIPIENT.