How to Make a Folded Cloth Mask
By Christianne Labelle
Step one: Gather your materials
You will need: cotton fabric,
flannel/flannelette for lining (Best
option but use what you have),
scissors, glue gun and sticks, ruler,
needle and thread (any colour),
ruler (any type), ribbon/elastic (not
pictured), wire (this is “craft wire”
from Dollarama. Pipe cleaners work
too.)
Step Two: Cutting
Cut one 9.5”x9.5” square out of
each fabric. You should have three
squares of the same size.
Step Three: Line them up
Stack your squares like so. Right
sides of your cotton fabric together,
with your lining on top.
Step Four: Pinning
Draw a line ½” from the top, then
pin all three pieces together across
that line like so. Also note the sides
of the lining have been trimmed.
Trimming will help you later on, I
recommend trimming ONLY the
lining (fabric on top) ½”
Step Five: Sew
Sew down the marked line. You
don’t need to anchor your stiches.
Only sew on the lining, do not sew
beyond the edge of the lining
(Again, this will make things easier
later on.)
Step Six: Press
Press open your seam with a hot
iron. Separate it between your two
cotton fabrics. Then, fold the mask
so the two right sides are out and
press the fold. You should have a
nice sharp fold. This will be the top
of your mask.
Step Seven: Adding the wire
Bend your wire to the right length.
More layers of wire give you a
better shape. I bend mine into
thirds, about 5”.
Step Eight: Glue in the wire
Only put three small dots – in the
middle and one at each end. This
will be enough to hold the wire in
place while you stitch it in, but not
too much to reduce shaping ability.
Step Nine: Stich in the wire
Thread your needle and stich the
wire in place. You will do this three
times - once next to each point of
glue. Place the needle under the
wire and make sure it comes out
only through two layers of fabric (if
it goes through all three pieces you
will see it on the other side.) You
only need three or four passes.
Tip: Snip the hem a little so the
mask doesn’t get bulky with your
stitches.
Step Ten: Sew the other side
Now its time to sew up the bottom.
Use your hands to flatten the mask,
ensuring that each layer is smooth.
Then draw a line ½” from the edge,
pin and stitch down the line.
Remember: Only stitch over the
lining, do now sew across your
cotton fabrics. You’ll see why in the
next step!
After you’ve stitched up the
bottom, turn the mask right side
out. Align the mask so the wire side
is at the top. Press the bottom seam
of the mask to get it nice and flat.
Step Eleven: Iron in the sides
Now you’re ready for the sides.
Here you can see me opening the
side so you can see the open seam
at the bottom. Fold the front fabric
inside the mask and press. Repeat
on the back side, folding the cotton
fabric overtop your lining, so that
on each side you will have the right
sides folded in together. Iron it nice
and flat. See next picture for
finished product.
Step Eleven Cont’d
This is what the sides of the mask
should look like.
Step Twelve: Fold the mask
This part takes some practice. You
are going to fold it three times.
Orient your mask so the wire in on
the top. Take the top ~2” and fold it
down, the fold the very top back up
again. See the sequence of three
pictures to the left
Step Thirteen: Repeat
Holding the first fold in place,
repeat the process a second time,
then a third.
Step Fourteen: More Pressing
This is how it should look after
folding. Hold the folds in and flip it
over to make sure they are straight
on the back side too. You may have
to unfold it and do the process
again if its crooked. When satisfied,
press in the folds with a really hot
iron. Press the front and back really
well. Pin the fold in place, but leave
the top fold unpinned
Step Fifteen: Add the ribbon
Cut four strands of ribbon (at least
14” long each). If using elastic, cut
two strands 5-7” long. Place the
mask under the presser foot, but
before you put the foot down, tuck
the ribbon/elastic into the mask.
Make sure you tuck in far enough
for the needle to catch it. Anchor it
really well, then sew down over top
each of the folds. You may need to
push/pull it through.
Stop halfway down and tuck in the
second ribbon (or other side of
elastic) into the bottom of the
mask, then continue. Anchor well.
Tip: Before sewing up the other
side, go back to your ironing board
and check the alignment of the
folds. Sometimes with all the
pushing the fold get sewn a little
wonky and the mask looks crooked.
Reshape the other side so that the
mask is straight, press well again,
pin, then repeat step fifteen on the
second side.
Tip: If you’re giving the mask to
someone else, tug gently on the
ribbon to make sure its been
anchored well enough inside.
Step Sixteen: Finishing
Snip all the threads off, then finish
the ends of the ribbon how you
prefer. You can fold it and sew it,
use iron-on glue, or burn the ends
with a candle (my preferred
method.)
After that, you are done!
Happy Sewing!
