Mask Making Step-By-Step

Mask Making Step-By-Step Sew on machine or by hand

This tutorial will instruct you on how to make a two layer protective mask that you can hand sew or use a sewing machine to make. It is a preferred style that is already in use by medical professionals in our area. Medical professionals who are using this style also prefer that you use some sort of ties and not elastic. Ties will enable the mask to be held more securely than the elastic and have a better fit along the sides of the face. These launder very well and we recommend that you put them in a zippered pillowcase to wash and dry them.

The best thing about this mask style is that it is easy to make, it fits well over your nose and hugs your face, AND you can make it with materials you already have in your home. The goal is so that folks do not have to spend money on anything other than thread if they want to make these for anyone beyond their own family.

Materials: You don't need any special materials other than needle and thread. You have all the materials you need right in your home! For the bottom layer that will be toward your face, use a 100% cotton t-shirt. For the top layer, use a tight weave 100% cotton sheet or tight weave 100% cotton fabric if you have it. It helps to iron the t-shirt and the portion of the sheet you will be cutting so that it will be easier to cut and sew the material, but this is optional. To make the four ties needed per mask, you will cut one inch strips of the t-shirt that are 18 inches long. You can also make the ties with paracord or shoelaces or ribbon cut to 18 inch lengths if you have it. If you use ribbon, we've found that it is the weakest link in the process and can easily fray after many uses and washings and may need to be replaced. If you have satin approx 2/5 inch ribbon, feel free to use it, but making ties out of the cotton t-shirt really is the best.

CLICK HERE for small, medium and large PDF mask patterns to print out

Print out the above PDF for small (approx 7.5" x 5.5"), medium (approx 8.5" x 6") and large (approx 9.5" x 7") mask patterns. The first measurement is from one side of the face across the nose to the other side, the second measurement is from top of nose to bottom of chin (see picture at end of instructions). Cut out pattern on the red lines and then trace them onto thicker paper or cardboard and cut those out. It is easier to trace the patterns on the cloth if they're on thicker paper. If you need an even smaller mask than the small size, you can cut along the inner dotted lines instead.

For the t-shirt, cut through both parts of the shirt at once to get two pieces that match each other. Do not cut out over any graphics for the mask shape. If you are making them for donation, try to cut more mediums and larges and cut out smalls where you can to not waste fabric. Leave about 4 inches from the bottom of the t-shirt on both sides to make the ties (instructions for ties are in the next section). For the sheet, if it has a built in pattern on one side (like in the picture) fold it so that the pattern side faces each other when you cut it and you are cutting out two parts at once. The hardest part of the cutting was not having scissors that were sharp enough. If you want to buy sharp scissors, Gingher dressmaker shears are terrific and are available on Amazon.

This portion will instruct you on how to make the four ties from the t-shirt. First, you will cut off the thick hem on the bottom of the t-shirt (don't discard the hem) (see first picture). Then you will measure about an inch in and cut straight up through both parts of the t-shirt. You'll cut the resulting loop into two 18 inch strips (second picture and sometimes you can get three strips out depending on the size of the t-shirt). You will do this one more time and then you will have 4 strips. You will hold each end of a strip and pull gently and the material will curl on itself to look like a tube (third picture). You do not have to be precise about the cutting or worry that your cuts are not perfectly straight. It's OK because these are just for the ties and no clothing inspector will be coming to check your work! Just do your best! The bottom hem can be cut into two ties (it's the "smile" part of the last picture). The thick hems on the arms of the t-shirt can also be cut out to be ties (they are the "eyes" in the last picture). For the ties, you can cut over the graphics.

You will sew 3/8 inch in from all sides of the mask you cut out. You can mark all the way around, or just mark 3/8 inch in on the corners (first picture). I made a 3/8 inch guide to use to mark the corners of the cloth instead of using the ruler each time (second picture). You also could print out another pattern of each size and cut on the dotted lines to use to trace the sewing lines all around the cloth (third picture).

First, you will sew along the large curved edge of the t-shirt, then do the same for the sheet fabric. The "right" sides of the fabric should be inside touching one another. If you don't want to mark the sew line, you can just mark the corners and keep the right side of the sewing foot along the edge of the fabric as you sew. You will start 3/8 inch in from the edges. The stitch should be a tight straight stitch. Remember to do a back stitch when you start and end the side you are sewing. If you are hand sewing, use a tight straight stitch and secure the ends of your thread.

Then you will open both pieces and lay them on top of one another so that the "right" sides are inside and facing one another. I folded up the corner of the t-shirt layer in the picture so you could see what I mean. Line up the edges of the t-shirt and the sheet material.

Next you will sew the long sides of the mask leaving the short sides open. Start 3/8 of an inch in and finish 3/8 of an inch from the end according to the markings. I sew the longest side of the mask first (the side that has the pointy beak-like part that will go over the nose). When you get to the middle, I have two of the layers folded together to one side and the other two facing the other way as in the middle picture. Sometimes it's a little tricky to sew in this area because it's thicker. Then you will sew the other long edge the same way as shown the last picture.

Next you will turn the mask inside out so it looks like the second picture here. Flatten it out and line up the short edges.

Now you will sew each edge of the mask closed with two 18 inch ties inserted per corner. Fold in both edges of the mask about 3/8 inches in as shown the first picture and then insert one end of the tie folded in half in between the layers at the very top of the opening as shown in the second picture. Insert the tie to be even with the edges you folded under. You will sew down that edge and through the tie. Before you get to the bottom, you will add the last tie along the bottom edge and continue sewing to close up that side. You will repeat this process with the other side. This is the same process even if you use another type of tie, like paracord or ribbon.

Here is what a finished mask looks like and I am wearing a size medium in green and a large in the blue. Medium fits me and a large fits my husband.

If you will be donating the masks to a medical professional or anyone in need, we recommend either: (1) washing and drying the completed masks in a zippered pillowcase before you donate them, or (2) ironing them with a hot iron. This is because you will be handling the material so much as you make the mask. Wash your hands before you take them out of the dryer or start ironing and then put the completed masks in a plastic ziplock bag for delivery.

This mask was designed by Jennifermaker.com and I thank my neighbor for bringing this wonderful pattern to me and for making so many masks for my husband and his medical colleagues. Jennifermaker's website and a video tutorial for the mask is on the link on the PDF pattern for the masks. I made these instructions because I personally thought her explanation was somewhat difficult to follow because she was using a Cricut cutting machine, using 3 layers and filter material, and adding a nose wire. This pattern fits very well without the nose wire and we decided to keep it simple by not adding the extra layer. My other departures from the original instructions do not require you to iron the seams open or to baste in all four ties at once. I found that ironing the seams is not necessary and adding all four ties at once is more cumbersome. Lastly, her instructions call for washing the material before making it, but with all the handling of the material while sewing, it makes more sense to launder/iron to somewhat sterilize them after they are made.

If you wish to make extra masks beyond those for your family and would like to donate them for medical professionals in our area, please contact Luci McClure at leaders2serve@gmail.com or 610-529-5597. We are working with the Chester County (Pennsylvania) Medical Society to distribute the masks to those in need. May God bless you and stay safe!

Created By

Luci McClure

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Credits:

Photo credits by Luci McClure