Recycled Mask

The upcycled BEcycle mask system is a lightweight reusable clear mask adapter combined with a certified face mask.
The BEcycle mask is a work in progress.
See Use & Fit for more information

Design and Features

Mask BEcycle 1.0
Production ProcessRecycle
TransparentYes
Body MaterialFoodsafe PETG plastic (polyethylene terephthalate) from Beverage Bottle
Weight10 grams
Cost¢
FilterSurgical Mask
StrappingEar
Recyclable MaterialsYes
SizingVariable
Testing AvailableNo

Pros

  • Can be produced at home with common consumer materials in small batches
  • Most economical option
  • Ability to customize size, color, and materials for comfort and seal
  • Easy to replace consumer mask filter for single or limited use
  • Clear mask is easy to clean and treat for anti-fogging
  • Open source design includes production guide

Cons

  • Time consuming to create larger quantities
  • Learning curve to identify correct size and shape for individual faces to achieve seal
  • Responsibility to locate local skin-safe materials on maker
  • Filtration depends on ability to secure quality consumer mask or purchase medical-grade materials

User Guide


Assembly


Shell

1. Print cut out and assemble paper template with tape.

1. Print cut out and assemble paper template with tape.


2. Remove label from 2-liter bottle, clean. Fill with air, replace cap. Locate ‘seam’ and adhesive strip.

2. Remove label from 2-liter bottle, clean.
Fill with air, replace cap. Locate ‘seam’ and adhesive strip.


3. Center paper template on seam and tape.  Do not cover adhesive strip with template.

3. Center paper template on seam and tape.
Do not cover adhesive strip with template.


4. Trace edge of template (dry erase marker recommended).

4. Trace edge of template (dry erase marker recommended).


5. Rough cut plastic bottle with 1cm margin from traced line. Remove excess plastic, trim shell to traced line.

5. Rough cut plastic bottle with 1cm margin from traced line. Remove excess plastic, trim shell to traced line.


Sizing

6. Center mask shell on face using mirror. From top, mark each side of nose bridge.

6. Center mask shell on face using mirror.
From top, mark each side of nose bridge.


7. From tip of nose, mark each side for strap guide.

7. From tip of nose, mark each side for strap guide.


8. Mark base line 2cm below chin.

8. Mark base line 2cm below chin.


9. Mark corner of each mask leg 3cm in from base line. Add vertical lines following diagram.

9. Mark corner of each mask leg 3cm in from base line.
Add vertical lines following diagram.


Cutting

10. Cut slit 2mm on either side for strap guide.

10. Cut slit 2mm on either side for strap guide.


11. Cut slit one cm on either side for base line

11. Cut slit one cm on either side for base line.


12. Cut out mask legs to base line, rounding all corners and edges. Make sure there are no sharp edges. Wipe off dry erase marker

12. Cut out mask legs to base line, rounding all corners and edges.
Make sure there are no sharp edges. Wipe off dry erase marker.


Folding

13. Fold shell inwards following edge of the mask for gasket. Taper into nose bridge lines. Fold side legs in.

13. Fold shell inwards following edge of the mask for gasket. Taper into nose bridge lines.
Fold side legs in.


Taping

14. Place mask shell on face. To size mask, connect mask legs and open mouth.  Adjust to fit comfortably. Tape mask legs together.

14. Place mask shell on face. To size mask, connect mask legs and open mouth.
Adjust to fit comfortably. Tape mask legs together.


15. Cut tape to length of surgical mask, place on table facing up.  Place surgical mask facing up on tape aligning bottom edge (without metal wire).

15. Cut tape to length of surgical mask, place on table facing up.
Place surgical mask facing up on tape aligning bottom edge (without metal wire).


16. Center mask shell above cloth mask with 1cm overlap.  From center, roll mask over adhesive tape to attach. Pull surgical mask straps up through gasket to strap guide. (Optional) Surgical mask can be taped against mask.

16. Center mask shell above cloth mask with 1cm overlap.
From center, roll mask over adhesive tape to attach. Pull surgical mask straps up through gasket to strap guide.
(Optional) Surgical mask can be taped against mask.


17. (Optional) Bandage or tape can be used as cushion for nose bridge edge.

17. (Optional) Bandage or tape can be used as cushion for nose bridge edge.


Use & Fit

The efficacy of this mask depends on a good air-seal with the user’s face, between the adapter and the filtration material, and between the filter and the the neck. 

With regard to a seal around the face, note that the size and shape of the user’s face may necessitate adjustments in the folds. The in-folded margins at the clear adapter provides a smooth convex surface that can fit snugly against the user’s face, and keeps potentially abrasive edges of the plastic away from the user’s skin. Special attention should be given to the area around the bridge of the nose and the sensitive skin under the eyes. If necessary gaps can be filled, and rough surfaces covered, with clear comfort strips (we use these) or adhesive bandages.

A good seal between adapter and filter material can be achieved with adhesive tap.

With regard to sealing around the the neck and chin, we note that many facemasks come with an embedded metal strip on one edge.  Originally  designed to be bent around the user’s nose, our strategy is to put that the adapter under the chin, so it can be bent or folded as needed to produce a snug fit under the chin.

Prevention of general mask fogging

  • Masks will fog in humid or cold environments, when transitioning between environments, or when worn for an extended period of time while speaking or breathing heavily.
  • Fogging can be greatly reduced by placing a drop or two of liquid dish/hand soap on the mask and rubbing it on the surface round. Reapply as needed.
  • You can also switch between two masks every hour or two, to allow one to air out and de-fog.

Care & Sanitization

The PETG plastic bottles can be washed in warm soapy water.  It should be clean when it is put on, and should be cleaned periodically, especially after any possible exposure to pathogens. 

  • To clean and sanitize, peel the facemask away from the clear shell.
  • Remove any remaining adhesive strips
  • Wash the clear shell in soapy water.
  • Dry shell and replace the adhesive strips.
  • Replace facemask.
  • For full sanitization recommendations, follow Care + Sanitation documentation

Production and Distribution


Testing

The filtration and protection afforded by this system will depend upon the quality of the seal and nature for the filtration material or maks attached to the adapter. Because this is a hand-crafted DIY device, we haven’t provided standardized tests.


Recycling FAQ


Q. Can this mask be produced at home? What do I need?

A. Yes! No special tools are required to make this mask:

  • Straight razor
  • Scissors
  • 2-liter bottle
  • Mirror
  • Clear tape

Q. Can you use any 2-liter bottle to make a mask?

A. We recommend clean clear plastic bottles with the traditional capsule shape that are not dented or scratched. After the label is removed, the adhesive strip can be removed with hand sanitizer if it obscures the mask shell.


The BE mask is offered to the general public for general, non-medical purposes. In accord with FDA Emergency Use Authorization, it has been submitted for review to NIOSH. The safety and efficacy of any mask depends on fitting, sanitization practices, and filter materials. Any mask should be tested and fit to meet local needs and standards. Please see our user liability disclaimer for details.