ECOFIBER Mask
Lyocell Non-woven mask
A comfortable, effective, and eco-friendly alternative to single-use masks​.
Developed for The Mask Innovation Challenge: Creating Tomorrow’s Mask.
The Contest
In 2021, I designed two mask concepts for the Mask Innovation Challenge, focusing on fit, filtration, comfort, and sustainability—using biodegradable materials to reduce environmental impact.
MASK PROBLEMs
​
-
Issues include poor fit, discomfort, limited sizes, and incompatibility with glasses or facial hair.
-
Many masks lack certification or effective COVID-19 filtration.
-
Most certified masks use single-use plastics harming the environment.
​
Material
Research
​​
​
​​​
- Layers of cotton and silk have been proven to create static, which can prevent microscopic particles from entering mask.
​
​
- Lyocell is a biodegradable and hypoallergenic fiber made from eucalyptus pulp which can be used in woven, knit, and non-woven fabrics.
​
​​
- Yulex is a biodegradable foam made of rubber.
​
MaSk
Science​​
​
​​
- The mask must fit the face snugly without gaps.
-
The mask must be made of a tightly woven or non-woven material.
​
​​
- Static between fibers trap nano-particles.
​
​​
- Moisture negatively affects the protection of the mask.
​
Concept 1
Key Features: Innovative Design: Vacuum-formed Yulex foam gasket for a lightweight, comfortable seal. Prevents glasses fogging and creates breathing space. Materials: Biodegradable Yulex foam (natural rubber from Guayule shrub). Hypoallergenic Lyocell fabric (eucalyptus-based, low water use). Optional cotton and silk layers for proven filtration. Fit and Comfort: Sized XS-XL for adults, plans for children and larger sizes. Foam gasket seals well, ideal for sensitive skin. Filtration: Multi-layer high thread count fabrics with electrostatic silk for effective filtering. Comparable protection to N95 masks. Sustainability: Washable, reusable with a two-year lifespan. Fully biodegradable and compostable materials. Cost and Manufacturing: Approximate material cost: $2.30 per mask (excluding labor). Made via vacuum forming and traditional stitching.
Concept 2
Key Features: Innovative Design: BioKnit is a reusable, biodegradable mask made with circular knitting (like sock production). Combines fit, filtration, comfort, and sustainability. Employs cost-effective circular knitting with low waste and fast production. Features shaping, cushioned nose bridge, and machine-seamed edges. Final form created by steaming; includes nose wire and ear loops. Materials: Uses natural, hypoallergenic fibers: cotton, silk, Lyocell. Fit and Comfort: Designed for adults, kids, glasses wearers, and sensitive skin. Sized XS–XL based on NIOSH face shape data. Natural fibers provide breathability, moisture control, and skin-friendliness. Filtration: Based on research showing cotton + silk layers filter as well as N95s. Uses high-needle-count knitting, terry loops, and electrostatic effects. Possible treatments: chitosan or oxygen plasma for enhanced filtration. Sustainability: Made from biodegradable, compostable materials (Lyocell, silk, cotton). Zero waste manufacturing (all yarn used). Washable, reusable, compostable after 1–2 years of use. Cost and Manufacturing: Estimated cost: $0.28–$1.00 per mask (similar to socks). Low labor, fast production (~5 min per mask).
results
Although I didn’t advance to the funding round of the Mask Innovation Challenge, I recognized an opportunity to simplify my design and reduce manufacturing costs.
I refined the concept once more, streamlining materials to use 100% non-woven Lyocell.
Final Model
niosh Face Shapes
These are the five most common face shapes of the NIOSH anthropometric study:
Small, medium, large, long/narrow, short/wide.
Using Solidworks, I imported the 5 head shapes and created a molded mask for each shape.
ECOFIBER Mask
ECOFIBER Mask
Made from non-woven Lyocell, the Ecofiber Mask is molded into five sizes to comfortably fit a wide range of face shapes. Designed as a sustainable alternative to N95 masks, it effectively filters smoke, pollution, and airborne pathogens. An optional oxygen plasma surface treatment can enhance filtration performance. At the end of its life, the mask is fully compostable—offering an eco-friendly solution to traditional disposable respirators.
*Needs further scientific research
​
