Sterilization Wrap Mask Kit

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Product Overview

Circular Blu is now offering mask kits for at home assembly. 

Our mask kits include the following:

  • 320" of elastic (enough for two 8" pieces per mask if using around the head style)
  • One piece of 18 gauge copper wire ( 75" which is enough for 3.75" per mask)
  • Medical grade sterilization wrap SMS non-woven fabric (2 sheets, each around 36" x 72")
  • Sterilization wrap to make 20 two-ply masks

Supplies that you will need:

  • Sewing machine or needle and thread
  • Scissors
  • Ruler
  • Needle nose pliers and wire cutters

Directions for at home mask assembly:

1) Cut two pieces of the Halyard fabric 7” × 8” (mask body) The 7″ sides will be the width across the top and the bottom of the mask. The 8-inch sides will be pleated. Three pleats will make the final mask 4″ deep.

2) Layer the 2 pieces of 7″ x 8″ fabric on top of each other. Sew a 1/4″ inch seam on the 7″ sides.

3) Turn the mask right side out. Finger press and clip, topstitch 1/4″ from both edges on the sides you just clipped.

4) To create the nose piece, cut the wire into a 6” piece. Make a small loop on each end of the wire and press flat. The loops should be facing the same way. Insert the prepared wire into the 1/4″ seam on one of the sides you top stitched. Center the wire. This is now the top of the mask.

5) Mark 2″ down from the TOP edge of the mask on both sides. Make three accordion-style pleats along the 8″ side as follows: Make the 3 half-inch pleats starting at the 2″ mark and clip each pleat. Space the pleats one after the other and clip them to make the mask 4″ wide. Adjust the pleats accordingly. The pleats do not have to be perfect as long as the mask is 4 inches wide. This is important because if the mask is too short, it won’t go under the chin in some cases, and if the mask is too long, it could leave too much of a gap on the side of the face. Do not change the number of pleats as the bottom pleat is especially important to the curvature of the mask under the chin.

6) Sew the pleats down by sewing 1/4″ seam. Repeat on the other side. When finished, the pleats will all be going down.

7) It is now time to attach the elastics.  Take both elastics and place one at the top corner of the mask, and one at the bottom corner of the mask on the same side.  Stitch the elastics onto the 1/4 inch seam that was previously created, and then repeat on the other side.


Sterilization wrap is a medical grade SMS non-woven polypropylene fabric that has been tested by its manufacturer(s) to have a Bacterial Filtration Efficiency (BFE) of greater than 98% using two layers of material.  Sterilization wrap will be either blue, white, or a combination of both colors.

Due to the global shortage of N95 and surgical masks, masks made from sterilization wrap have been used by doctors in hospitals who are facing critical PPE shortages. A doctor at UF Health has stated that masks made from this material may be able to “block 99.9% of particulates, making the masks about 4% more effective at blocking particulate material than the N95 masks.” Now doctors across the globe are using this material for mask creation. The CDC recommends the use of “homemade masks” when no certified face masks are available. The mask design affects efficacy, and our Sterilization Wrap Mask has not been formally tested as of yet.  

Material used for creation of these masks is collected as clean post-industrial waste generated by the manufacturing of sterilization wrap. This could include trimmings, off-colored batches, or QC fails. The material is aggregated in a warehouse and baled, and shipped to be upcycled into masks. The baling of the material may cause the fabric to be wrinkled. The material is unused, clean and equally as effective as new sterilization wrap. It can be considered an upcycled product that would have otherwise been sent to a plastics recycler.

The Circular Blu team has been upcycling and recycling sterilization wrap into various products for nearly a decade and have been making masks from it since late in February 2020.


- These masks are not intended to be used as a replacement for any regulated medical device and have not been cleared by the FDA. 

- These masks should not be considered as a comparable substitute for medical equipment.

- These masks are not NIOSH approved.

- Circular Blu does not make any claims as to the performance of these masks and urges customers to do their own research on the topic in order to make an informed decision.

Related Reading Material:

Article Containing Doctor at University of Florida Health's Claims on Sterilization Wrap Masks

"I think This Idea Could Save Hundreds of Thousands of Lives": UF Doctor Creates New, Effective Mask From Hospital Materials

Example of Another Doctor Describing How To Make Homemade Sterilization Wrap Masks

Sterilization Wrap Material Specifications From Manufacturer Including BFE Testing

Providence Health's Sterilization Wrap Design Instructions

Lehigh Valley Health Network is doing its part by taking an innovative approach to extend the use of N-95 respirator masks

Community members launched a coordinated sewing effort to produce surgical masks for Cayuga Medical Center in Ithaca using sterilization wrap

***The safety and efficacy of facemasks using the materials and processes described here have not been formally evaluated. By accessing this information, you agree to hold harmless the authors and maintainers of this site for the acquisition or transmission of contagion associated with its use. Improvised masks should not be considered a substitute for commercial personal protective equipment (PPE).