Protohaven’s Ally Face Mask is an open-source, quickly-produced, well-fitting face covering. It’s faster to make than other fitted designs, and is more comfortable than flat or pleated designs.
It’s designed to be mass produced by anyone with a home sewing machine and basic sewing ability. No pleats, no curves, no fancy stitches. It requires only readily-available materials, the kind used for pillowcases and t-shirts. No bias tape to make or elastic to source. 10 an hour, 50 a day, 200 a week are reasonable outputs for a dedicated intermediate sewist. You could supply your whole neighborhood.
It’s also comfortable to wear. It doesn’t smash your nose or pull your ears, and it stays put when you talk.
You can start making the Ally Face Mask by following the free instructions below.
- Consumer sewing machine
- Thread scissors
- Point turner
- Safety pin (1)
- Straight pins (3)
- Seam ripper
- 100% cotton jersey knit fabric (one 28” x 1.5” strip per mask. Will be approx. 56″ after stretching)
- 100% cotton woven fabric (two approximately 5.5″ x 10.5″ pieces per mask, cut to shape)
- 100% cotton thread (preferably color-matched)
Patterns (Woven fabric)
Patterns are each sized to print on a single 8.5″ x 14″ paper (US Legal). Make sure the printer settings are set to “actual size”. Alternatively, they can be printed in two parts at 100% scale if using 8.5″ x 11″ paper (US Letter).
Small/Medium (fits most)
Large (optimized for larger faces)
Protohaven’s Ally Face Mask by Alexis Caldero is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
Based on a work at https://anest.ufl.edu/clinical-divisions/mask-alternative/#prototype2.
This design and these instructions are provided for free and as-is. Neither Protohaven nor the creators of the design and instructions offer any warranty or assume any liability for their use.