Introduction: 3D Printed Mask

About: Mechanical Engineering student at Colorado Mesa University with aspirations to transfer acquired knowledge into automotive industry.


The university for the remainder of the semester past spring break transitioned to online learning. For the engineering projects course, three alternative options were provided if groups were unable to continue with their original project. A mask, a face shield or a ventilator. For my individual project I decided to design a mask. With the shortage of N95 masks globally I felt this was a large need with more room to come up with a new design. The primary goal I set for this project was to create a mask with a relatively simple design, and for it to be usable for the everyday person.


3 3D printed parts (provided)

Strap materials (rubber band, Velcro, etc.)

Cutting tools

Soft, malleable material to cut for mask seal

Glue to secure

Step 1: What

This mask has three parts that comprise the entire design. The largest portion being the mask itself that fits to the user's face. The next part of the mask is the cartridge that fits into the mask by friction. This part will actually hold the filter in place, in the mask. The final part is the slide that will contain the filter by sliding into the hooks on the cartridge. This will secure the filter in place and maintain breathability. These three combined parts will create a seal around the user's mouth and nose.

Step 2: Disclaimer

  1. This mask is intended for ease of use. It is not guaranteed protection against COVID-19
  2. A 3d printer is required for this mask
  3. Rubber bands or other straps are required to secure the mask and have to be tight enough to create a seal
  4. In regard to filter material, it is up to the user to decide what material is put into the insert
  5. Make sure to cut and place filter material into insert as precisely as possible
  6. To add protection, one may cut a rubber material (yoga mat) in the shape of the part that is in contact with the user's face to create a more effective seal

Step 3: Design Process

The attached video provides a step-by-step guide into how I created the mask in Solidworks. Mirroring sketches and guided curves were the key to get a more contoured design for a user's face. I prioritized simplicity, and if I were to change something and spend more time on, it would be a mechanism to lock the seal into place. Sliding the seal into place it will rely on friction to stay in place. This is provided the user does not shake his/her head rapidly to throw the seal out, I am confident it will stay in place.

Attached is the STL files needed to print the mask parts