From our co-founder, Tracy Hoover
As the social distancing and closure orders worked their way through Wichita over the past couple of weeks, here at Groover Labs we decided that it would be worthwhile to start sewing some masks and wearing them. Now we are nearly at the point where masks will be required for everyone.
I did some googling two weeks ago, and here are some I remember from that first search:
https://www.instructables.com/id/DIY-Cloth-Face-Mask/
https://www.craftpassion.com/face-mask-sewing-pattern/
https://www.deaconess.com/How-to-make-a-Face-Mask
https://thestitchingscientist.com/2020/03/how-to-sew-a-face-mask.html
https://www.instructables.com/id/AB-Mask-for-a-Nurse-by-a-Nurse/
I just googled again, and there are a lot more now. The New York Times has at least two articles on how to make a mask:
https://www.nytimes.com/2020/03/31/opinion/coronavirus-n95-mask.html
https://www.nytimes.com/article/how-to-make-face-mask-coronavirus.html
I also looked for guidance on fabric, and it was pretty sparse. Here's the most authoritative source I found, but I had no way to evaluate its credibility:
https://smartairfilters.com/en/blog/best-materials-make-diy-face-mask-virus/
And there's some guidance here too:
https://www.owensborohealth.org/news-events/news-media/2020/fabric-surgical-masks-information/
There may be more guidance now, but I already made my decision so I'll talk about that.
There seemed to be consensus that cotton fabric was a good choice, so I went to JoAnn's and found some quilting cotton on the remnant table for $2 and $3 per yard. The print on the $2/yard fabric was Christmas related, so not ideal style-wise, but the price was right. I also asked my quilting mother-in-law for unwanted fabric from her stash. I washed it all in hot water, dried it and then ironed it flat. Don't skip these steps, no matter how tedious they seem. You'll shrink the fabric before you cut and sew, and it will be easier to work with fabric that is not wrinkled.
There are several variations on mask construction methods. You should check out each style and decide which one suits your needs, skills and supplies best. The method I chose requires some sewing skills, but it looks like the articles from The New York Times may be more suitable for those with fewer supplies, equipment and skills.
I ended up deciding to do the AB Mask. It's a good mask that can be worn directly over the face or as a cover to prolong the life of an N95 mask. But it takes a fair amount of effort, so it may not be the best choice for mass production. It also requires some sewing skills, as I mentioned.
I have been able to reduce production time by cutting a bunch at once, and then doing the same construction steps on all the masks before moving on to the next step. If you decide to do this one, it takes 24.5 inches of 44 inch wide fabric to make three masks. You'll have a bit of leftover fabric that you can use for additional ties. You may end up with some Franken-masks at the end, using all your leftover bits.
If you are going to try to mass produce, construct a complete mask before you go on. You'll get the lay of the land and also figure out where you can streamline your process.
I've made 20 so far and have another nine in the pipeline. Each of us in the family has two — one to wear and one to be in the wash. I gave one to our postal carrier and to one of our members. I saw a request from a friend on Facebook and gave her some as well.
I'm about to send a few to my brother in New Hampshire. His significant other works in a hospital ER. I wanted to give one to my UPS guy this morning, but I was at home and all the spare masks were at Groover Labs. So I think I might try to carry a spare to give away when the opportunity strikes.