Fabric Face Mask Assembly

Fabric Face Mask Assembly

Educational institutions are looking for ways to protect students. Here at the College of Engineering at the University of South Florida, we’re absolutely committed to helping with this cause. We have included here a set of instructions and laser cut and 3D printable files. You do NOT need a laser cutter to make these… you don’t need any special equipment other than a sewing machine and pins. See the PDF downloads below for free individual patterns at different sizes.

Bias Tape

To make bias tape, simply cut long 2″ wide (50mm) strips and run them through this 3D printed part available for free here and iron:


I used the 5cm with wings but you can choose the one which mostly closely matches and scale it appropriately.

Alternatively, you can buy a bias tape maker or just buy bias tape directly.

Cutter Files and Patterns

Load up the Large size for the average adult male, Medium works well for adult females, and XL for fuller faces. If you need a smaller pattern still, just increase the seam allowances when stitching starting with the medium pattern and shorten elastic from 8 to 7 inches. You can also tie a knot in the elastic after completion.

Latest Version 5b – Open Source and Free – Share/Share Alike

Hand Cut and Printable Instructions

Laser Cutter Files

Easy to clean and comfortable to wear
Interior is a soft flannel which is breathable and provides good filtration

Tips and Tricks

You don’t need any advanced equipment to make this as featured in the video. You can simply cut the pattern out by hand onto a fabric of your choosing.

Add an Aluminum wire or pipe cleaner to the nose bridge bias tape path to allow an air-tight fit.

Making masks in batches where tasks are repeated all at once and then the next step is attempted results in the fastest assembly. (Basically, do not make these one at a time if you want to make them fast.)

Whether cutting with the laser cutter or by hand, do not cut the fabric on the bias. What do we mean by that? Be sure the fibers are running up and down, left and right relative to how one would wear the mask. The close ups in the video showcase this but basically, the straight edge of the pattern should line up with the fibers of the fabric used.

Test the ear loop length during the pinning process to ensure the mask is a comfortable fit. If you’re not sure what your size is, you can assemble a printed paper mock-up and pin elastic to it for a sense of the feel.

If these are uncomfortable to wear for extended periods of time and you have access to a 3D printer, you can print these ear reliefs for comfort:



The guideline here is presented as a project under a Creative Commons, copy/publish, Attribution Required, NO commercial use, Modify Adapt license. Please use this to help yourself during these difficult times. No warranty is provided with these plans and USF, the College of Engineering, and myself are held harmless in the event of damages.  This face shield design and specifications are being provided as a free service to the community during this public health emergency.  This face mask is not intended to prevent specific diseases or infections. Individuals or organizations that manufacture face shields utilizing the design and specifications are responsible for any federal or state regulatory requirements that apply to the manufacture of face shields intended for medical use, and are responsible for informing health care providers to which the masks are supplied that they are responsible for decisions regarding appropriate personal protective equipment for their personnel. Individuals and organizations are free to use, copy and share this design and specifications, including for commercial manufacture, without payment of any fees or charges, but may not assert ownership in the design and specifications, ownership of which belongs to the Board of Regents of the University of South Florida and/or the individuals who created the design. EXCEPT WHERE SPECIFICALLY PROHIBITED BY LAW, NO WARRANTIES OF ANY KIND ARE OFFERED FOR THE FACE SHIELD DESIGN AND SPECIFICATIONS,  INCLUDING WARRANTIES OF NON-INFRINGEMENT AND FITNESS FOR A PARTICULAR PURPOSE