COVID-19, Unmasked

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This research and design project is the result of a mass pandemic situation that asks for a seamless and accessible alternative to mass-produced N95 masks. In a fabricated, alternate reality where viral infection is common and rages through populations if proper protective equipment is not worn in all areas of life, these mask prototypes are crucial. In the last few weeks, cleaning supplies, masks, and even toilet paper have been very hard to come by in stores and online in America. In said alternative reality, we assume there are no masks to go around. Even in real life, due to major production lines in China and India being closed due to the virus, production and shipping have slowed, and commodities such as N95 masks are no longer being fabricated and distributed fast enough to keep up with the pandemic.

In many cities nationwide, hospitals are asking people competent with a sewing machine and who have extra time and fabric, to make and donate masks to be used in non-hazardous hospital wards. Although there is no way to create homemade masks that are one hundred percent effective at preventing the novel Coronavirus, there are several different ways to make masks that may slow the spread if worn properly and sanitized often.

My first impression as I began to hear about the rapid spread of Coronavirus in mid-February, was that people are simply being careless in the countries where it was spreading. As time passed it became evident that in fact,  this was not the case. While the virus has a relatively low mortality rate, it should not be taken lightly. Still, by the time Coronavirus became “real” in the eyes of the American public, people reacted ridiculously, exhibiting strange hoarding tendencies, and mass hysteria. To address the chronic deficiency of masks, I have been working towards figuring out some ways to slow down the spread, and calm people down by designing accessible, reusable, and sustainable. While the most important part fashion forward masks. 

Initially, the Centers for Disease Control and Prevention (CDC) and the World Health Organization (WHO) did not recommend wearing masks if you had not already contracted Coronavirus, unless you were caring for someone who was exhibiting flu-like symptoms. However, once the virus had progressed to a more aggressive state, and given the long incubation period for COVID-19, they are now recommending that everyone wear cloth face coverings in public settings where other social distancing measures are difficult to maintain (for example, grocery stores and pharmacies), especially in areas of significant community-based transmission.

The CDC also advises the general use of simple cloth face coverings to slow the spread of the virus and help people who may have the virus and do not know it from transmitting it to others. They have published on their websites that masks fashioned from household items at low cost can be used as an additional, voluntary public health measure. They say that cloth face coverings should not be placed on young children under age 2, anyone who has trouble breathing, or is unconscious, incapacitated or otherwise unable to remove the mask without assistance.

Design

When I began constructing my “alternate world” in which all of the residents would have to wear masks like these prototypes in order to protect themselves, that universe was further from our current reality. Since Coronavirus has spread so quickly in the last few weeks,  my alternate reality is seeming more like our actual reality than previously planned. There are many different kinds of masks out there and after some research it became very apparent that it is paramount to strike a balance between comfort, wearability, and functionality. 

Nurses who wear masks day in and day out have reactions to bad fabrics, have skin reactions to things around their ears and necks. In addition, the N95 masks cannot be worn continuously, and cannot be laundered or sanitized in a fast and effective way. To prevent sores and infections, developers have to start thinking of new ways to fix this.

I had read one story about a nurse whose ears became rashy and sore from hours of wearing the elastic bands, so she got creative and made “Princess Leia” buns around which she hooked the elastic. My first prototype, I made the elastic purposely long, so I would be able to hook it around my hair rather than ears. While this design idea works well for women with long hair, it is not so feasible for people with shorter hair. 

Materials

Throughout this process, I’ve been studying different fabric mask-making techniques, and collecting different materials with which to bring them to life. It was difficult to come by materials for building my prototypes, so it began with paper sketches, then I made some drafts out of paper towels and tape. 

I made my first prototype out of a cut up t-shirt, and before making more I found some fabric scraps and remnants that are of different cotton amounts mixed with other materials at a local craft store. Some of the fabrics are better looking than others, and some are softer. I hoped to strike a balance between something that looks nice and something that feels comfortable for hours on end.

Prototype 1 

For my first prototype, I knew I was planning to hand sew it to test the waters of mask design and see how sturdy I could make it without a sewing machine. I used the cuttings from an old t-shirt, black thread, and some elastic bands I already had. 

I learned many things during the creation of my first mask prototype. While the cotton of the upcycled t-shirt that I used was easy to sew with, it tended to roll a little at the edges. It is easily washable and can even be put in a dryer,  but I decided I definitely wanted to consider different materials. I went to Joanne’s fabrics to their “remnant” section, looking for a few different cotton blends that would be a little bit stiffer, so that my next iteration would hold its shape better. I knew I did not want it to irritate the skin, and in addition I wanted it to have decent breathability, while still being protective.

I also decided that I would need to find a good alternative to elastic. Most stores would not have elastic readily available during a pandemic, and I also had a particularly thick and uncomfortable elastic on the first prototype. If I would continue to use elastic, it would need to be thin and comfortable on the backs of ears.

I only put two pleats on the first prototype mask, since they are difficult to make consistent without a sewing machine. On my sewing machine prototype, I planned to have more, for a more form-fitting mask. 

Prototype 2

For my second mask prototype, I found a soft orange cotton blend fabric with a tight weave. Since it was another from the “remnants” bin at Joanne’s, the color was not ideal but it turned out to be easy to sew on the machine and gentle on the face. It was also a good shape for fitting in the paper towel filter in. 

After deploying this prototype I learned that I should most likely make something with two layers of fabric next, and with easily adjustable straps for larger or smaller faces. As for face fit, adding more pleats was definitely a good move. It withstood the laundry machine, and passed the lighter test.

For the next iteration, I decided that I would like to try and use a sturdier fabric on the outside layer of the mask for structural reasons, and on the inside I would use the same soft orange fabric. I also decided I’d like to test the structural integrity of hot glue, as opposed to sewing on a machine, to see if that is a viable option for those who do not have sewing machines.

Prototype 3

For my third prototype, I was really pleased with how the hot glue held the product together. I was concerned that it might fall apart in the wash, but on a hot and gentle cycle, it stayed intact. The main issue that this mask presented was that it’s unconventional shape made fitting the paper towel filters in from the sides rather difficult.

The lack of pleats and easy shape makes it the most successful design in terms of time spent to functionality and comfort. Because the hot glue helps the mask hold its shape pretty well, a wire nose piece was not required, but in my next iteration I would plan to implement some aluminum wire to reinforce the nose shape.

Prototype 4

  For the design and construction of my fourth prototype, I decided to approach from a different standpoint. I consulted the CDC’s website looking for their recommended mask shapes, and perused youtube to see what other designers had made. Gathering my notes from the previous prototypes, I sketched out my final plan.

As you can see, I decided to go back to the sewing machine, since after washing prototypes one through three I noticed very little washing machine wear-and-tear on the second iteration.

The filter fit well and was easy to take out and remove in my third, glued prototype, so I designed a shape heavily influenced by it. The fabric was soft but sturdy, and the aluminum wiring helped it keep its shape around the bridge of the nose. Two layers of delightfully colored fabric keep it fashionable and unique. Taking thin elastic out of old waist bands was the key to success in mask prototype 4.  The thin elastic is comfortable around ears and stretchy to fit most face sizes. It has no pleats but the overall cut allows it to fit most faces comfortably. This will be the end of my prototyping for now, and I feel pretty satisfied with it.

Testing & Washing

Both the WHO and the CDC advise washing fabric masks often, ideally between each wear. Washing on hot and air drying seems the best option, especially for hand sewn and glued masks. It is important to replace the paper towel filter often, and take out the aluminum wire before washing.

As for testing if your mask made from household scraps and fabrics is functional, many sources report that if you cannot blow a lighter out through the mask then it is sufficiently air tight. Ideally, it should help prevent the spread of the novel Coronavirus. I tested each prototype with its filter in and recorded the results. All face coverings were sufficient, although the third and fourth prototype felt most secure.

Identity & Comfort

One of my big concerns following functionality and comfortability, is fashionability. People love the ability to customize and make something their own, especially something that they have to wear every day. The entire situation of viral infection is unfavorable and stressful, but if we’re going to practice safety and social distancing, we need to be a little bit happy about aspects of it. Staying at home, spending more time with pets, doing personal improvements, staying healthy, keeping busy, and even enjoying the ways of protecting yourself is imperative. Since so many people are seeking accessible home handicraft activities, research and development of good ways to make things like hand sanitizer and face masks is crucial.

Mask fashion has been in society prior to the COVID-19pandemic, but it has always been rather niche. Communities who frequent raves and festivals use them as dust and debris protection, and as fashion statements. Masks with teeth, colors, and patterns are widely available, but are not thick or protective enough to stop coronavirus spread. However, the principle of fashionability can easily be translated into and combined with functionality.

If I continue to research how to make these masks even more effective and multi-functional, I think I would also look into how to incorporate essential oils and aromatherapy into the design. One thing people dislike about N95 masks is the factory smell, but a drop of a pleasurable scent can not only clear the sinuses, but also soothe the user and help relieve allergy symptoms, which may be mistaken for COVID symptoms.

Outcomes

From this four-week research engagement, I’ve been able to articulate and answer these questions: With the goal of promoting safety in light of the coronavirus pandemic, what medium and design would result in the most effective protection against an aggressive virus? Furthermore, what tools can be used to effectively promote resilience and sustainability? 

Designing a mask and sewing by hand proved possible, but the results were not beautiful nor fashionable. Making a mask with a sewing machine in both prototypes seemed most effective, and also quickest. As for shape, the third and fourth style seemed to be the most adequate. I have designed what I believe to be the most effective prototype so far, the fourth iteration exhibited by Matthew. Ideally, upcycling comfortable cotton fabric scraps keeps homemade masks as sustainable as possible, and when combined with paper towel filters and good shape design, they are effective enough for use at grocery stores and outdoors until a pandemic begins to pass, or official N95 masks become available to everyone.

To promote resilience and a sense of fun, I would want to dive more into how pandemics like this change fashion and how we interact with one another. Masks of course cover up a large portion of our faces, which we use extensively to express our emotions. The ability to  design and decorate these masks, and design shapes that allow us to see and to express ourselves with our eyes is critical. If I continue this research, I would like to develop something a little more futuristic, and perhaps with artificial intelligence features that could represent our emotions electronically through the masks.

Tech & Tools

Cardboard, tape, hot glue, fabric scraps, sharpie, string, elastic, cotton twine, pins, sewing machine, paper, pencils, aluminum wire and paper towel.

Participants

Jenna Lateano, Lukas Pecson, and Matthew Bohlen.

All through safe, social distancing methods. Precautions were taken.

Professor

Amanda Jensen

Information Design – Media Arts Project

Sources Cited 

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