N95-Style Platypus Mask

The Rydge Platypus Mask is an excellent replacement for the N95 masks when the N95’s are not available. It fits snug around the face creating a nice seal, and while it’s not NIOSH certified, it has been fit tested for keeping particles out. The Filti fabric used on the inside has been tested at 0.3 microns at 95% filtration for 0.3 microns and larger. The Halyard H100 creates a moisture barrier on the outside, while still allowing air to pass through for comfortable breathing.

Supplies Needed

            – Filti Fabric

            – Halyard H100 Fabric

            – 6 in Pipe Cleaners

            – 1/4 in Elastic cut to lengths of 13” and 11.5”

            – 3/8 in x 3/16 in Weather Stripping (We use Duck Brand)


Tools Required

            – Impulse Sealer

            – Ultra Sonic Welder (a sewing machine may be used instead for the elastic) 

            – Ruler

            – Scissors



Step 1: Cut the fabric

Follow the template below to cut the Filti and the H100 fabric.

For those of you who have laser cutters, here is the SVG file: Platypus Laser


Step 2: Seal the edges

Take one cut sheet of H100 and put it to the fuzzy side of one sheet of Filti.         

Place the fabrics’ straight edge on the impulse sealer blue side down. Press firmly to seal edges together. Wait a few seconds to let it cool. Peel off. (Pulling straight off can tear the seal)

Place the pipe cleaner in between the fabric layers close to the seam. Place back on sealer blue side down on the other side of the pipe cleaner to create a pocket. Press firmly. Cool. Peel off.

Seal the other straight edge.


Step 3: Attach Elastic

Using the ultrasonic welder, tack the elastic ends on to the straight edges of the mask about ¾ – 1 in away from side edge. The 13 in elastic strip attaches to the straight edge with the pipe cleaner, while the 11.5 in strip attaches to the other straight edge. 

Note: It takes some practice to get the welds right. It helps to have the weld perpendicular to the elastic, so it goes across it. Also, think of it as a stapler: quick hard press. Too slow, and the welder will time out before it actually touches the mask.


A sewing machine may be used in place of the welder. Zig-zag stitch over the elastic 3 times.  As long as the stitching is close to the edge of the mask, the punctures from the needle won’t affect the overall seal of the mask.


Step 4: Press the Side Seams

Fold the mask in half matching straight edges together, white sides together on the inside.

Place the slanted edge of the mask on the impulse sealer. On the highest setting (8), press firmly. Continue to hold firmly a few seconds after the timer light goes off. Release arm and let cool for a few seconds. Peel off.

Repeat for flip side of the seal of the same seam.

Repeat on other seam.

Alternative Seams: Using the sonic welder, tack the seams to together then fold over the edge. Tack again. Seam edges down, place on impulse sealer and press firmly. Only one press is needed per seam. This method takes stress off the seam itself and gives a cleaner look to the edge.


Step 5: Attach Weather Stripping

Flip mask inside out.

Cut foam to just short of the length of the mask.

Attach foam to the Filti fabric covering the pipe cleaner. Press firmly.

Peel off paper backing.

Flip right side out and press again to ensure strong adherence.


Step 6: Distribute!

Rydge Technologies
PO Box 226
Centerville, Tennessee 37033
United States

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