Another boat style - adapted from the patterns of others



320 gsm of spunbond polypropylene - for about 80% protection.
OR 480 gsm of spunbond polypropylene - for about 80% protection

This was an oval of four or six layers of 80 GSM SBPP. That sewn in the oval shape 
from the rectangle with the nose wire sewn in. The snipped outside the sew line. Then two major left to right sews, then the turned up (top) and turned down (bottom). Then wedges cut out of the throat area to tighten it. Lastly two sleeves for the round the head elastic.

It fits well. A six layer version isa little harder to make and gets you to 92% PFE (MakerMask test data)

For the cotton ancestors of this mask there was a turn inside out stage after an initial sewing 
together of two rectangles/hexagons. That stage can be skipped entirely - SBPP is a very 
different fabric type.

Making one

Template

You have choices. Smaller faces - 20.5 cm wide. Larger faces 21.5 cm wide.

The smaller white template: I can fold 1m wide cuts of fabric into six layers with that - only just as there is almost no fabric to cut off in that dimension.  The brown one can't have that 1m folded into six. Only into five, and there's a good amount to cut off with that.  You can make more masks with the smaller template.


   Cutting the fabric off the roll

With my 1m x 10m roll of 80 GSM SBPP:  The white line in the cut mark. I'm using the roll itself as the "straight" to guide the white pen.  There there were three people for one sewing machine each mask would be 8 mins each.




Four layers one being made (11 mins)


How I calculate the filtration efficiency


MakerMask.org paid for some Nelson Labs tests on spunbond polypropylene: results mapped to a predictive model here

More recently, I supplied masks for some tests at a North American University (who presently wish to remain nameless): which shows 
  • the six layer one (480 GSM) at 92% - same as the maker mask prediction
  • the four layer one (320 GSM) at 87% - better than the maker mask prediction 

Why I don't use ordinary fabrics

I used to. I wasted nine months researching that: generally the higher the filtration the worse the breathability

One for a pal (Roger) that is 6 x 80 gsm for 92% F.E



Variations

That one more layer of 38 gsm SBPP adds 1% more filtration.
Making of video for the red-lined at the top of this blog entry is here: youtube

The red one features the twist during sewing described above. 
The yellow one does not and it does not look as good when 
placed on your face. You can see the effect of that twist here:



Here's the yellow one folded flat. I could be mailed like that. 
It also has not had the section taken out of the bottom, so is 
looser under your chin - not as good fit.

















 

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