Abstract: A face mask include a bulbous area that reduces contact between the wearer and the mask, with the inner surface texture and material adapted to be comfortable to the wearer. The bulbous area may be equipped with a filter retained by slots at the edge of the bulbous area, with the inner surface texture and material of the filter also adapted to be comfortable to the wearer. The mask may be knit with seamless transitions between wearer-contacting surfaces and the bulbous area, which enhance the comfort of the mask. The mask may include silvered yarns for antimicrobial properties. Furthermore, the bulbous area increases the effective surface area of the mask on both inhalation and exhalation, unlike pleats that collapse on inhalation.

Abstract: A method of forming a spacer fabric includes performing, via a knitting machine, an iterative process. The iterative process includes: knitting a tether from a first point to a second point on a first fabric layer; extending the tether from the second point to a third point on a second fabric layer to start formation of a tether segment; temporarily holding the tether at the third point via one of a temporary holding needles; extending the tether from the third point to a fourth point on the first fabric layer; temporarily holding the tether at the fourth point via another one of the temporary holding needles; extending the tether from the fourth point to a fifth point on the second fabric layer; and knitting the tether from the fifth point to a final point on the second fabric layer. The tether segment is released from the temporary holding needles.