COVID-19 DIY Face Mask

Designed by Mark Fuller

The ingenuity of man never ceases to amaze me. Ingenuity, along with will-power and compassion are what will get us through these trying times.


My team is working diligently to provide support where we can best assist. In parallel, individuals on my team are making a difference, too.


Individuals like Mark Fuller. Please have a read & share.

From Mark:

mark & his mask


Step one: Research potential types of filter media options. 

CDC Guild lines HCP use of homemade masks:

In settings where facemasks are not available, HCP might use homemade masks (e.g., bandana, scarf) for care of patients with COVID-19 as a last resort. However, homemade masks are not considered PPE, since their capability to protect HCP is unknown. Caution should be exercised when considering this option. Homemade masks should ideally be used in combination with a face shield that covers the entire front (that extends to the chin or below) and sides of the face.

Step three: Product Development. 

Several iterations: MVP-1, MVP-2, Rev 1 for release.

Design objectives:

  1. Additive friendly

  2. Low filament use

  3. Fast printing

  4. Simple design

  5. Seals to face

  6. Flexible filter media options

  7. Easy to manufacture

  8. Shop-aid must be 3D printed

  9. Open source design

  10. Parametric model in common 3D modeling software

  11. Only use household items

Step two: Define objectives and research options on open source platforms. 

Other options were either not designed for additive or took >10 hours to print. 

Step four: More revisions & testing.

Print, solicit feedback from open source community. Suggestions included:

thinner nose area, more flexible frame, design which accepts larger strings.

Rev 2 printed and tested.


Step five: Print.

Filter media template & 3 different sized masks: Small, Medium, and Large.


filter medium template


small, medium, large


Step six: Hepa filter tear down.

Step seven: Optional attaching method.


Step eight: Printed around the world.





America Makes has created a COVID-19 Health Care Needs and AM Capabilities Repository, connecting Designers and Manufacturers with Health Care Providers. Please visit this link to learn more on how you can contribute.

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