A respirator (10) that has a mask body (12) a harness (13) and an exhalation valve (14). Both the harness (13) and the exhalation valve (14) are secured to the mask body (12). The exhalation valve (14) comprises a valve seat (20) and a flap (22) that has a surface (57) that has been ablated. Through use of an ablated flap the flap characteristics can be better fashioned to achieve desired valve performance. The valve flap can be fashioned to remain closed under any orientation but also to open with minimal force or pressure from the wearer s exhaled air. A valve having these qualities provides a respirator that is more comfortable for a person to wear which can be particularly beneficial to workers who wear respirators for extended time periods.
