Introduction: The Sealer Mask - 5 Minutes to Face Sealing / No Fogging COVID-19 Personal Protection

The Sealer Mask is a simple personal protection mask project that can be built in under 5 minutes using highly available household materials and tools. The tight fitting frame described in this Instructable allows you to either create your own high performance mask quickly or improve the performance of your existing mask.


  • No sewing required
  • Made with everyday, ordinary household materials
  • No special tools required
  • Custom sealing fit for the shape and size of your face

Features and Benefits

  • Adapts to all sizes of women, men, and children
  • Works great with beards
  • Can be used in combination with any cloth or non-N95 mask to improve protection


Solid copper wire is extremely pliable yet can take on a rigid shape that forms to an individual face. By creating a loop of wire then shaping it to meet the curves of your face, a custom seal is made. This copper framework is then attached to the face using simple rubber bands or elastic. Additional copper wire can be formed to provide strain relief behind the head while providing a simple mechanism to adjust tension.


  1. Use on top of an existing mask. Many people will choose this option if they have trouble with cloth masks fogging glasses or they simply want to increase protection while in public.
  2. Add 2-3 layers of microfiber blue shop towels to create a comfortable mask with disposable filters. The tension between the frame, the filters and the face holds everything in place. These towels have been shown to filter particles down to 0.3 microns. See as an example.
  3. Add a cloth layer from an old T-shirt to add a design
  4. Go crazy and connect the filter fabric directly to the frame for a more polished look!


Copper is well known for its antiviral and antibiotic properties. Early studies of SARS-CoV-2 (which causes COVID-19) show that the virus can live on copper for less than 4 hours. In addition the copper frame and elastic material are heat resistant and can be disinfected with bleach, alcohol, boiling, or steaming. Since the disposable filter is separate it is easy to discard and quickly decontaminate the Sealer Mask.



12 gauge solid copper wire (stripped): 1-2 feet

Standard rubber bands: 8 pieces

Blue shop towels - microfiber type (optional if using with an existing mask)






Wire Cutters

Step 1: Cut the Wire to Length

Strip, measure and cut a length of 12-gauge solid copper wire. I have not experimented with stranded copper wire but it tends not to hold its shape very well. 14-gauge and 16-gauge solid copper wire will probably work as well but has not been tested.

For a 6 foot tall male start with 13 inches of copper wire. For smaller faces shorten the wire to a length that comfortably surrounds the mouth and nose. For a 5' 9" female 11 inches should be close. If desired use a piece of dental floss to measure from the bridge of the nose, looping around the mouth and back up to the bridge for a custom estimate.

Step 2: Shape the Copper Wire

Shape the copper wire into a circle leaving about 2 inches of wire overlapping.

Use the pliers to twist the wire together to form a ring. It is helpful to start twisting at the center of the overlap.

Twist so the exposed ends of the wire are facing outward so they will not contact the face.

OPTION: It is also possible to use an electrical butt-splice to create the ring without the ends protruding. However, since this requires obtaining a butt-splice and using more specialized wire crimpers this method is not currently shown.

Step 3: Pre-shape the Copper

Bend the copper wire circle into a two dimensional shape as shown in the picture. This shape should look more or less like the outline around your nose and mouth.

The blue shop towel pattern shown in the pictures above can be used as a rough guide for shaping the wire and as filter material.

Step 4: Custom Fit the Copper to Your Face

Using a mirror press the copper wire shape to your face, bending it to match the contour along the nose, around the mouth and under the bottom lip above the chin.

You will now have a 3D shape that should seal comfortably around your nose and mouth when tension is applied.

If there are gaps, simply keep bending the wire until the gaps are eliminated.

Step 5: Add Straps

Wrap the rubber bands around the copper frame as shown and make a two rubber band chain to create each of the four tensioning straps.

Step 6: Make Strain Relief Straps and Attach

Cut two additional pieces of copper wire and bend as shown in the pictures.

The purpose of these pieces is to attach the rubber band straps in the back and provide strain relief. The angle of the V-shaped bend in the copper can be increased or decreased to adjust the tension of the Sealer Mask to the face.

Step 7: Make Final Adjustments and Add a Filter

A very tight seal around the face is possible. I've deliberately made the rubber bands very tight for the photo but the final adjustment stage should allow you to make this a very comfortable mask. During testing I wore this for multiple hours at a time while at home and exercising.

A decorative cotton pattern on top of the blue shop towels may be added to personalize the mask.

Or, if using a homemade cotton mask, simply add this frame on top to create a seal.

To make your own pattern for the filters simply add the piece of fabric you choose underneath the frame and trace around the edges. This will give you a pattern to cut out as many alternate filters as you need.

It is also possible to attach fabric to the frame itself but that is beyond the scope of this Instructable. The intent here is to offer a simple, high performance design while not requiring any specialized sewing skills.

Stay safe out there!