Sustainable 3D Knit PPE

During the COVID pandemic, I designed and developed a seamlessly 3D-knit face mask produced from single continuous strands of yarn with zero material waste and no cut-and-sew operations. The mask utilized a breathable three-layer knit architecture with integrated antibacterial and antifungal yarns engineered directly into the structure; delivering filtration, comfort, and durability without additional treatments or coatings. Elastic edge zones and ear loops were seamlessly knitted as part of the same unified structure, creating a self-adjusting, pressure-free fit that accommodated a wide range of facial geometries while maintaining a consistent seal. The project demonstrated how advanced knit programming and material-driven design can replace traditional multi-part PPE construction, and the resulting product was recognized and rated as a top-performing face mask by multiple influencers, EDC experts, and industry publications.