Introduction: DIY Exhalation Valve for Mask

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This is a modification for a medical mask that will release pressure off of the straps which will let less air in from the sides due to a pressure drop from a one way valve that is made from a bottle of soap.


- Bottle of soap (This example uses the one shown, but any bottle of soap/shampoo with a similar pump will work)

- Mask (n95 is the one that is shown because that is the most commonly referred to)

- Gorilla Glue or super glue

- Basic hand tools for disassembly

Step 1: Step 1: Disassembly

Disassemble the soap container.

First, I separated the cap from the bottle by unscrewing.
Then I removed the top from the plunger by unscrewing. Next, with force I removed the tube from the chamber and by tapping the chamber, the smaller ball came off. Next, I used a hacksaw to remove the cap of the bottle. It could probably be removed using force or by using a knife, but a hacksaw was the quickest way. I then removed the top cap by taking off the flanges with an xacto knife. After this, all the pieces could separate from the chamber and it was completely taken apart.

Note: When using sharp objects make sure to use proper eye protection, never cut towards yourself, and put objects in a vice if available.

Step 2: Step 2: Assemble the Valve

A material to make dowels/pins is needed. You can use wire from the screw or any other wire. Assemble the valve as it was. Cut the chamber and the tube down to size and drill two holes to make the inside valve and the smaller ball stay in place. Put the dowels into the holes that were made. See attached PDF for dimensions.

To cut dowel, probably the best idea to use wire clippers or scissors. Use eye protection to prevent material cut from flying into eye.

Step 3: Step 3: Prepare the Mask

Cut a hole to a diameter of 0.3 inches in the mask. You can use the valve to trace. Make sure the fit is tight on the smaller side of the valve.

To cut the mask, scissors or an exacto knife are reccommended. Make sure to use a cutting mat or a material that you do not mind scratching.

Step 4: Glue the Seam

After inserting the valve into the mask, put a glue seam on both sides. Be generous because you want the seal to be airtight.

Make sure to be extra careful with superglue. It is very easy to glue fingers together and they will need to be ripped off. Also the fumes are noxious when it is curing so do not inhale directly and use in a well ventilated area.

Step 5: Files

Stls of the two assemblies are uploaded if you want to look at it in 3D. The drawing package is also attached. Drawings are to scale.