Kovacs first discovered the fabric when he worked for a dressmaker. The fabric was originally made into a woman's dress and the marketing of such a product would be linked to Dr. Manhattan. The product's first customer was a woman named Kitty Genovese, who was unhappy with the dress, calling it "ugly" and refused to buy it. Kovacs thought differently however, and took possession of the fabric for himself, saying it was "very beautiful." At home he used heated instruments to shape the fabric into a full head covering, a face he "could look at in the mirror."
In a way it is true that this is his "real face" as the fluids react to his expressions, where without it, he usually never shows any facial expression, except anger or indifference.
Rorschach is expected to appear in the upcoming Doomsday Clock, which will conclude the story of DC Rebirth. His mask appears on the lenticular cover of Issue #1, transforming into the symbols of DC's Trinity.