Materials:
● Two 8″ cotton fabric squares for outside of mask, washed and dried
● Two 8″ cotton fabric squares for inside of mask, washed and dried
● 1/4″ elastic or 1/4″ – 3/8″ wide grosgrain ribbon or double-fold bias tape
● wire or pipe cleaners or twist ties (optional)
● filter (optional)
● pencil or other fabric marking tool
● sewing machine
● scissors
● printed face mask pattern
Supply information: Use 100% cotton fabric that has a tight weave, if possible. Batik and poplin fabric are good
choices. You could also use a pillowcase or sheet that is tightly woven. Quilting cotton is also fine. If you’re uncertain
about the quality/weave, you can hold your fabric up to the light and see how much light filters through. Less light
showing through is better. Pre-washing all fabric is recommended. For more information on best materials to use for DIY
masks, check out this article.
Update: Instead of pins, use clips such as Clover Mini Wonder Clips to hold pieces in place. This will prevent any extra
holes in the material.
For the elastic, I find that 1/4″ flat elastic works best. You can use elastic cording or other elastic that you have on hand.
If you can’t find elastic, you could use hair ties, but I find they’re a little uncomfortable and not adjustable.
Instead of elastic (and the one that I prefer) is ribbon or fabric ties. These can be sewn to the four corners of the mask or
threaded through the casing using two longer ties (which is harder to tie because it’s loose for me). Grosgrain or twill
ribbon is better than satin ribbon because they don’t slip as much. Double-fold bias tape can also be used and you can
make your own by cutting strips of fabric 1 1/2″ wide (doesn’t have to be on the bias, straight is fine), folding it in half
along the length (wrong sides together) creating a center fold, and folding the raw edges to the center fold. Then press in
half along the center fold and topstitch along the outer edge, making a 3/8″ wide tie. The length should be about 16″ long
each.
Adding wire to the nose area is optional but very effective. Wire should be thin enough to bend easily and can be found
in home improvement and craft stores. Pipe cleaners, floral wire, gardening wire, bag ties, etc. can also be used. Wire
cutters are helpful for thicker wire.
Optional filter insert: If you want to add another layer of filtration, you can insert a HEPA filter into the open pocket.
These come in the form of air filters or vacuum cleaner bag filters and can be found in home improvement stores. If a
filter is not available, you could use a non-woven sew-in interfacing such as Pellon 930 Midweight. Whatever you use,
make sure you can still breathe through the mask easily. Again, this is not meant to replace a medical-grade filter system
or personal protective equipment.
Face mask instructions
● Cut out inner and outer face mask pattern pieces on the solid lines.
● With fabric right sides together, pin pattern pieces to fabric or just trace cutting lines onto fabric. Cut out inner
and outer face mask pieces.
● Transfer solid casing line (1 1/2″ from raw edge) onto the wrong side of outer face mask pieces using pencil or
other marking tool.
● With right sides together, sew 1/4″ seam along the inside center face mask pieces. Repeat for the outside center
face mask seam.
● Cut notches into the curved seam allowance just sewn or use pinking shears to trim curved seam allowance. This
will reduce bulk and help the seam to lay flat. Gently press to one side.
● Turn under 1/4″ along the short side edges of the inner face mask and press. Stitch in place.
● With right sides together, pin inner and outer face mask pieces along upper edge, matching center seam. Stitch
using 1/4″ seam allowance (backstitching at the beginning and end).
● Turn right side out and press seam, extending 1/4″ fold along the outer face mask edge.
● Top stitch in place 1/8″ from folded edges.
Repeat the above process on the bottom edge – right sides together and matching the center seam.
● Turn under 1/4″ along the short sides of the outer face mask and press.
● Fold this edge again (5/8″) so that it meets the pencil line and press.
● Stitch along the inner folded edge, creating a casing for elastic or ties.
Add elastic or ties to the mask. If you have elastic, cut a 12″ length and thread through the side casing. Tie a knot and
adjust it as needed. Once it’s comfortable, you can slide the elastic around so the knot is inside the casing (optional).
If you’re using hair ties, you can cut them in half and sew them to the outside instead of feeding them through the casing.
Otherwise, you will have to place them into the casing before stitching the casing seam closed.
For ribbon or fabric ties, you can attach them two ways. The first way (my preference) is to sew each one to a corner of
the face mask. The length should be about 16″ each. This takes a little longer to put the face mask on, but it’s adjustable,
the mask sits tight against the face and it makes it easy to remove the mask partially without having to completely
remove it.
The second way to attach ribbon or fabric ties is to thread a longer tie (36″) through the casing on each side and tie it
behind the head. This method is more difficult to tie it behind the head tightly. It also gathers the short sides of the face
mask which might give you a better fit but it also can create gaps.
Optional nose wire: Cut a length of wire or pipe cleaner to 3 1/2″. Turn under the ends a tiny bit and crimp so that there
are no sharp edges. I used thin florist wire so I folded a 6 1/2″ piece in half and covered the exposed ends with electrical
tape. Sew a channel for the wire 1/4″ away from the upper edge and about 1 1/2″ on either side of the center seam. Insert
wire through the side opening. Stitch channel ends closed.
Filter: A filter or another layer of material can be inserted at this point. Since I don’t have access to any filters, I’ve used
some interfacing just for example purposes. I cut a rectangle 5″ x 7″ and then cut a curve on both top edges by estimating
it (eyeballing it). You could also use the pattern as a guide and even sew the interfacing the same as the inside mask
pattern and then trim to fit.
