Reusable Face Mask with Fabric Seal

The problem with these 3D printed masks has typically been poor fit and lack of proper seal with the face. I have attempted to fix these issues with this remix of junaling's design: https://www.thingiverse.com/th...

This mask is meant to be printed in PLA, which can be molded to the contours of your face after placing it in near-boiling water for just a few seconds. Take care to avoid submerging the the airway opening, because if this warps, the cap may not fit right. See video.

After molding, you should get a pretty good seal (you can check by covering the airway with tape and trying to breathe in). But some unfiltered air still might get in around the edges. So this is where the "fabric seal" comes in. Rather than try to remove all leaks, we just filter them the same way the airway is being filtered.

This is done as shown in the video, using a circular piece of cotton fabric roughly 10" (25 cm) in diameter. it is held in place using the insert, then completely covers the outside of the mask, and is held in place by your face once fastened. This way, the air coming through the outer edges of the mask is also filtered.

Clean the mask the same way you do your hands, with soap and water. The PLA will warp in the dishwasher, so wash it by hand, or submerge it in alcohol. For the cotton fabric, simply throw it in the washing machine. It may be useful to have several pieces of fabric on hand to swap out.

I make no promises about the effectiveness of this design. Cotton is clearly not the same as an N95 filter. But hopefully it's better than nothing, and once all the single-use masks are gone, this kind of reusable mask may be what we are left with. Use at your own risk.

I've left enough space between the cap and the mask to add an additional filter of some kind if you like.