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.
- 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.