How to Sew a Surgical Face Mask for Hospitals
Many makers have asked for a pattern to sew homemade surgical masks for
hospitals. The DIY pattern in this post will teach you to make a standard pleated face
mask with elastic ear loops.
This pattern has 2 layers of fabric, and an internal pocket in which you can add
additional layers of disposable filtration material if desired.
If you can’t find or don’t want to use elastic, there are also instructions for using
fabric ties.
Surgical Mask Shortage
Currently, the supply of surgical
masks is at a critical all-time low
throughout the entire nation.
Orders for the standard disposable
masks used in hospitals are back-
ordered, due to the high demand for
protective equipment.
So, because of these supply
concerns, many hospitals across the
country have requested homemade
surgical masks as an emergency
stopgap measure.
According to the CDC, fabric masks
are a crisis response option when
other supplies have been exhausted.
An Important Distinction
Homemade face masks are not as effective as the N95 filtration mask recommended
by the CDC, and are not a substitute for proper PPE.
Rather, they are meant to respond to the hospitals’ requests for emergency backup
masks.
Sources for further reading: Cambridge Study, Nature, Occ. Env Med, Annals Occ
Hygiene)
I strongly caution you before you spend time sewing these masks:
1. Follow the CDC guidelines as the situation develops.
2. Contact your local hospital and clinic to ensure that they are accepting masks,
and that any masks you make will meet their individual guidelines.
Homemade Face Masks are a Last Resort
The Centers for Disease Control and Prevention (CDC) has explained that in times of
crisis, homemade masks are acceptable as a last resort. On the CDC
website, Strategies for Optimizing the Supply of Facemasks, they explain that while
homemade masks are not a substitute for PPE, they can be used in settings where
facemasks are not available.
HCP use of homemade masks:
In settings where facemasks are not available, HCP might use homemade
masks (e.g., bandana, scarf) for care of patients with COVID-19 as a last
resort. However, homemade masks are not considered PPE, since their
capability to protect HCP is unknown. Caution should be exercised when
considering this option. Homemade masks should ideally be used in
combination with a face shield that covers the entire front (that extends
to the chin or below) and sides of the face.
Some Hospitals are Requesting Homemade Surgical Masks
Some hospitals and clinics (like this one) are accepting donations of homemade face
masks.
Before you spend time sewing a large batch of masks, please call first to ask if they
are accepting them. You should ask if this pattern will meet their requirements. You
should also ask about safe drop-off/pick-up procedures.
What Fabric Can You Use to Make A Face Mask?
Researchers at Cambridge
University tested the
effectiveness of a wide range of
household materials for use in
homemade masks. They
measured how well the
household materials could
capture and filter small
particles.
Test data shows that the best
choices for DIY fabric masks are
cotton t-shirts, pillowcases, or
other cotton materials. For this
pattern, I used a tightly-woven
premium quilting cotton fabric.
Using a double layer of material
for your DIY mask adds a small
increase in filtration
effectiveness.
DIY Surgical Mask Pattern
Materials
• 100% cotton fabric (with a tight weave, like quilting cotton)
• 1/8″ flat elastic, or additional fabric to make fabric ties
• fabric scissors
• ruler
• pins or clips
• sewing machine and thread
Cut List
For an adult size mask:
• Cut 1 fabric rectangle 15.5″ long and 8.5″ wide
• Cut 2 pieces of elastic, each 7″ long
For a child-size mask:
• Cut 1 fabric rectangle 13.5″ long and 6.5″ wide
• Cut 2 pieces of elastic, each 6″ long
For elastic ear loops:
• Cut 2 7″ long pieces for an adult mask
• Cut 2 6″ long pieces for a child mask
For fabric ties, if you aren’t using elastic:
• Cut 4 rectangles 18″ long by 1.75″ wide.
Fold the long sides to meet in the middle, then fold in half again to encase the
raw edges. Stitch down the length of the rectangles along the edge to create the
ties.
Step 1: Sew to the top side,
with pocket
Fold the fabric in half, with the
right sides facing each other.
Sew along the 8.5″ width edge,
using a 3/8″ seam allowance.
Leave a 3” opening in the center
of this seam to create an
opening for the filter pocket,
and to allow the mask to be
turned right side out after
sewing. In the picture above,
I’ve marked this opening with
pins.
Don’t want a filter pocket?
If you don’t want or need a
pocket, that’s totally fine. You’ll
still need to leave a hole in order
to turn the fabric right side out.
After you attach the elastic and turn the mask right side out, sew the opening closed.
Step 2: Pin Elastic
Turn the fabric so that the seam with
the pocket opening is centered in the
middle of one side.
Optionally, stitch to reinforce the
seam: Press the seam open and
topstitch or zig-zag stitch along both
sides of the seam for a neater edge.
Pin one piece of elastic to the top and
bottom of the short sides of the
fabric rectangle to create an ear loop.
Place the ends of the elastic 1/2 “
from the top and bottom edge of the
fabric.
The length of the elastic will be
sandwiched inside the two layers of
fabric, so it will be on the outside
when you turn the mask right side
out.
Alternative – Use fabric ties:
If you can’t find elastic, or prefer to use fabric ties, you can use 4 fabric ties, one in
each corner. Each tie will be 18″ long. Sew one tie in each corner, being careful not
to catch the ties in the side seams.
You can also use twill tape, bias tape, or strips from cotton jersey (t-shirt fabric).
The finished mask will then be worn by tying the fabric strips behind the head.
Step 3: Sew the Sides
Sew the sides of the facemask.
Backstitch over the elastic or fabric
ties to secure them. Trim the corners
with scissors.
Turn the mask right side out and
press with an iron. You can use a
pencil to push out the corners.
Step 4: Make the Pleats
Create three evenly spaced 1/2”
pleats. Pin the folds in place, and sew
along the sides. Make sure all pleats
are facing the same direction.
The finished mask will be about 3.75″
tall.
When the mask is worn, the pleats
should open downwards to prevent
any particles from collecting in the
fold pockets.
Troubleshooting the Pattern
Can’t find elastic?
I’ve heard from many people that
are having a hard time finding
elastic. If you can’t find elastic to
make the ear loops, you can make a
mask with fabric ties instead. The
ties will go around the back of the
head, rather than around the ears.
To make ties, you can use ready-
made 1/4″ twill tape, double-fold
bias tape, or cut long strips of the
same tightly woven cotton fabric
you are using for the rest of the
mask.
To make fabric ties:
Cut 18″ long strips of fabric, 1.75″ wide. Fold the long sides together (lengthwise or
hot-dog style) so that they meet in the middle. Then fold the strips in half again
(lengthwise) to encase the raw edges. Stitch down the strips along the edge to create
the ties.
If you wanted these straps to have a bit of stretch, you could also cut long strips from
cotton jersey or knit T-shirt material.
Whichever option you choose, you’ll want to make 4 pieces about 18″ long, and
attach one strip to each of the corners. The mask will fasten by tying the straps
behind the back of the head.
What about metal around the nose to help it fit better?
To help the mask fit better around your nose, you can insert a length of flexible
metal to the top inside of the mask, through the pocket insert opening before
forming the pleats. Then, you can topstitch down around the metal insert so that it
stays in place. I’ve seen people use pipe cleaners, floral wire, or twist ties.
What can you use as a filter?
It is so important that everyone understands that while wearing a cloth face mask
can offer some level of protection, it can’t protect against viruses the same way that
an N95 mask can.
In testing, a layer of HEPA vacuum cleaner bag or HEPA air filter seems to perform
the best. However, it will be harder to breathe through.
If you are sewing for hospitals, they may have their own medical grade filters. Always
call before you sew to check their requirements.
Disclaimer: This pattern has not been industry-tested and is intended for educational
purposes only. The decision to use this device is solely your own.
See the original post, comments, and discussion at:
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