Assembly

Video or Text: Feel free to watch our video, or read through the assembly instructions below.

UnSewn™ Mask Detailed Instructions, 15:46

WHAT YOU WILL NEED:
(2) Dry Unscented Swiffer® Sweeper sheets
(2) Soft, dry unscented nonwoven sheets (see NOTES *)
(8) Twist-Ties
(1) Piece of thin, sturdy cardboard, at least 2″ x 3″ (see NOTES **)
(11) thin rubber bands, 3″ x 1/8″
(1) Drugstore Roll Paper Tape, 1″ wide

TOOLS: Ruler; Pen; Stapler; Scotch tape; Sharp Scissors
A fabric cutter is optional but will make things easier.

NOTES:
* For the soft unscented sheets, you can use Swiffer® sheets, or our UnSewn™ sheets. We hope to have UnSewn™ sheets available by mid-July 2020.
** For the cardboard, we used dry cleaner shirt cardboard. Cardboard from the back of an old notebook or a half-gallon milk or juice carton will work; or even flat plastic from the side of a gallon jug.

STEP 1: CREATE THE 2-PLY FILTER LAYER, AND “SANDWICH” IT.
A. Place the two Swiffer® sheets as follows: the bottom sheet is vertical, and has its textured (embossed) side facing up. The top sheet is horizontal, and has its smooth side facing up. Cut each sheet so it is 7-1/2″ tall (vertical distance), and 7″ wide (horizontal distance). You have now created a 2-Ply Filter Layer. Save the scraps for dusting, etc.
B. (The following will apply after UnSewn™ sheets become available, hopefully by mid-July 2020:) If you are using UnSewn™ Skin Contact Sheets (below left), just place the 2-Ply Filter Layer (vertically) between two (vertical) UnSewn™ sheets. UnSewn™ sheets are already cut to size, and both sides are smooth. To obtain UnSewn™ Skin Contact Sheets, please order through our Kickstarter page.
If you will be using Swiffer® sheets for your skin contact sheets (below right), place two Swiffer® sheets vertically, with the embossed sides touching each other (smooth sides out). Cut the sheets just as before (7-1/2″ x 7″). Then, use these just as we use the UnSewn™ skin contact sheets, but make sure to keep the embossed sides in (toward the 2-Ply Filter Layer), and the smooth sides out.
STEP 2: PAPER-TAPE YOUR 4-PLY MASK.
A. You should now have a 4-ply stack of sheets. Mark the center of the top sheet with a ballpoint pen. Cut (2) two-inch-long pieces of the 1″ wide surgical tape. Place these pieces horizontally, immediately above and below the center dot. Press smooth.
B. Cut pieces of the 1″ wide Paper Tape: TWO 3/4″-long pieces; EIGHT 1″-long pieces. Place each piece of tape so it is half-on and half-off the sheet, as shown. Position as follows: (1) Center: 3/4″ pieces. (2) Sides: 1″ pieces. (3) In-Between: 1″ pieces.
Turn the stack of sheets over and fold down the tape edges. Press smooth.
STEP 3: STAPLE FOLDS, AND APPLY NOSE PIECE.
A. Turn the mask back over, so the marked-and-taped center is up. Fold the taped edges in to the center. Staple the right and left sides of each edge as shown. Make sure the staples go all the way through the material.
B. Scotch-tape four twist-ties together into a flat bar. Affix a single, long piece of Scotch tape (red arrow)–a bit longer than the twist-tie bar–into the center of the top flap and press it down firmly. Then, with a second long piece of Scotch tape, affix the twist-tie bar onto the first long piece of tape.
STEP 4: ATTACH SIDE ANCHORS, TWIST-TIES, and HEAD STRAPS.
A. Make two rectangles of cardboard (or similar material), each 3/4″ wide by 3″ tall. Place marks 1″ in from each long end. Place the rectangles at the sides of the mask. Staple two staples through each rectangle as shown on the arrows at right, one at the lower mark and one near the lower edge.
B. Fold four twist-ties in half. Place two on each side, under and over each side anchor. (To make sure they stay in place during stapling, you can fold them slightly back in toward the mask.) Then staple two more staples through each anchor, one through the upper mark and one through the upper edge.
C. Make two rubber band chains by looping rubber bands through each other as shown. Attach a 6-band strap to the top twist-ties, and a 5-band strap to the bottom twist ties. Turn the mask back over, so the flaps are facing up. Tape upper and lower flaps together at their extreme right and left edges, using a piece of paper tape 1/2″ wide x 1″ tall.
Now that you’ve made an UnSewn Mask, see how to use it.