How to make a mask

The product can be made and assembled in appropriately resourced school DT Depts.

Keep SOCIAL DISTANCE in mind, if others are helping put these together.

Set up a workstation process, so you are far apart from each other.

Wear gloves as you work and wear a 3M mask as you work.

Check your temperature, make sure you are well enough to do this.

Step 1 – Materials

Visor – A3 sheets of Acetate 250 micron

Headband – 1,1.5 or 2mm thick plastic (we used vacuum forming plastic). 0.5mm polypropylene works too.

Headband backing – A strip of upholstery foam for comfort ~160 x 25x 25 (or blocks of modelling foam ~30mm x 30mm x 20mm if you can’t get soft foam sheet.)

Headband fixing – Velcro self-adhesive. Each needs 3 small squares (A & B sides) or double-sided tape

Headband – Elastic (we used 25mm width). Each needs ~350-400mm

Step 2 – Visor

You can make the visor part from acetate as you can see in the diagrams. When we began this process we had designs with a radius on them (see diagram below). This meant using a laser cutter. The visors had to be done one at a time on the machine, stacking them meant the laser cutter fused the sheets. Same with a CNC machine.


While this means you don’t have soft rounded corners, health workers have used the more angular design and say it works fine. So now we can make many more masks. The laser was a bottleneck.

Download the zip file below, unzip. The drawings and files for parts are in there, ignore the visor with rounded corners for now, cut the visor on a guillotine.

Download not working? Contact us (Right click HERE for alternate download)

NB. Google Chrome might warn you about this download. Click KEEP.

Step 3 – Headband

a) From the zip in the last step you will have the file for the headbands and positioning jigs

b) Add your material sheets as you normally would and cut as many headbands as you can from your material

c) Cut your upholstery foam into 25mm strips (we used a bandsaw), then cut again into ~160mm lengths. Foam blocks can be cut on the bandsaw too.

Step 4 – Assembly


You can either fix the visor to the headband with 25mm double-sided tape for a ‘permanent’ join (visor can be sprayed/sanitised regularly) , or velcro them on to allow for replacing the visor if it gets damaged/badly contaminated.

a) Stick the strip of upholstery foam or 3 x foam blocks (using the positioning jig) onto your headband, on the ‘back’.

b) Stick the 3 velcro squares (A Sides) onto your headband “front” using the positioning jig. Make sure the velcro is “eyes up”. This prevents it slipping.

c) Stick the 3 velcro squares (B Sides) onto your visor near the top using the positioning jig (see below). Make sure the velcro on the visor is “hooks up” to prevent slipping.

d) Thread the elastic through the slot and fix with a stapler or hot glue.

e) Spray the headband with anti-bacterial alcohol spray if you have it and place in a large ziplock freezer bag or supply as is and advise user to sanitise.

Whats in the download

Faceshield components.dtd

Faceshield cutting list and manufacture plan.doc

Headband single slot nested.dtd

Headband single slot nested.dxf

Faceshield components.jpg

Faceshield components.dxf

Hopefully this is a useful guide to allow you to make these quick masks. The PDF file below is a bill of materials and some instructions.

Thank you to who sparked the initial idea for a quick and simple mask.

Thanks for helping your local health workers.

Face shield cutting list, manufacture plans and CAD files available here:

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