DIY Fitted Face Mask

Bybarbmaker

What has everyone been up to?! Yes, do not roll your eyes… I have a lot of fabric and abundance of ideas. I’m just keeping hands busy and mind content. My gift to you; a DIY fitted face Mask with pattern.

Yes, I know!

I know, I know; before you tell me that this mask will not replace a N95, I know. Depending what fabric you use will depend on the amount of particulates it will filter. There is some interesting data here. I’m not a scientist, but I can draft a pattern.

I’m a maker, and spending safe time in my house I wanted to be productive and make a difference for those I care for if even just a tiny bit. DISCLAIMER: I am not giving any assurance that this will protect you from all airborne virus or like. Research carefully and make your own decisions.

My main purpose is to make a mask that fits me as I like. My international students have the etiquette to wear masks even in the best of times many years ago and I have marvelled at how stylish and comfortable some are.

You will need:

  • Fabric (t-shirt knits, tight weave cotton, dish towel fabric, vacuum bags)
  • Thin elastic (1/8″ – 1/4″)
  • soft bendable wire
  • sewing machine, thread scissors…
  • PATTERN

Using my ‘mug’ and a mask I designed this pattern (print full size, no reduction on letter size paper) to fit over the nose and give space for the lips. Yes, it has a seam down the middle, you choose. Some have pleats and are quite flat. I find the leakage around the nose can be a problem, and this has a wire shaping as well.

In my research for fabric and material I found that vacuum bags provide good filtration. I do have some HEPA vacuum bags, which have 3 layers. One thing to consider is comfort and breathability and the vacuum bags work quite well.

UPDATE: I am getting a lot of comments about the possibility that these vacuum bags have fibreglass in them. It seems to be a debate, so please choose wisely. This article also addresses it.

One way to help make them more efficient is to layer, as I did here with 3 layers. Cut 2 pieces of each layer. Such a great way to use up some of the scraps of ice-dyed t-shirt fabric.

Easy Assembly:

Double up 2 layers and with right sides together, sew the front centre seam. Sew a 3/8″ centre seam of lining as well.

Since every face is different, it a good idea to make a test one. Adjust as you like from there. Here centre seam is sewn.

To keep the shape I press open the centre seam and stitch flat.

This will keep the form of the mask firm.

Since the seams may get thick trim back at top and bottom.

Just like a Pillow:

To join the inside to the outside, is much like making a pillow; sew all the way around (right sides together) and leave an opening to turn right side out.

Note: If you want to attach elastic before turning add to each piece at dots marked on pattern and loop inside. I like the option of adding later so that adjustments can be made; your choice.

After sewing clip corners off without cutting stitches and trim seam allowance as close as possible.

Such a nice shape:

Turn right side out and push corners out with a chopstick or skewer.

The nose bridge fits better if wire is inserted. I used a thin floral wire that it a slight bit stronger than a twist tie. Bend in the ends for safety. An alternate way is to use wired ribbon. Another great option is to use strips cut from tin cans (like the top flap of a sardine can or tomato can) See this post for details on how to make it iron-in.

Before top stitching the perimeter of the mask, insert the wire as close to edge as possible and pin/clip. Top stitch all around and close the opening.

To add elastic after turning loop a bit under so it is 2x secure and stitch on.

UPDATE: Due to some shortage of elastic, An alternate is using some t-shirt fabric cut in 3/4″ strips. It rolls when pulled and has some stretch and is soft on the ears. You can also adapt this Pattern to have a casing and open ends for filter pocket. See this post.

The Form & Fit:

The fit is quite comfortable. To size smaller a slight reduction in print size can work.

Everyones nose is different! If you like, you can reduce the height as seen on pattern. The nose wire can be shaped well to fit around your’s.

I wear glasses so I always find issues when wearing my masks for concreting! Yup, when you are a ‘designer’ you are much fussier!

If you would like an even flatter fit over the nose for glasses see this pattern as an adaptation of this pattern. We are all quite different (imagine how many fits of jeans we have)

This mask scoops under that chin of mine as well!

TADA! I can feel a bit better. I especially like the ‘vacuum bag’ face masks. They should be cleaned washed after each use. I would not just through them in the washer due to the wire. If you put them in a bag the heat of the dryer will hopefully kill anything.

Some more effectiveness can also be had by spraying the fitted face mask with a solution of citric acid and allowing to dry. Leaving them in the sun lets the UV also disinfect. Again, do your research and make good choices.

I’d rather be making pretty things than medical supplies or a fitted face mask… But this gives a bit of comfort anyways. DO be careful out there my friends!

See the look in my eyes!? The wonder, the caution, the hope of better times soon… but as a very very wise person said to me quite often; things coud be much worse so be grateful.

Yup, it’s odd, I’m a grandma now but I really wish my ‘Mommy’ was here to reassure me right now…

As a chid I used to watch my mom design fashionable hats from scratch; so now it’s my destiny to design some masks… like this and this.

I'm an artist & I make things... all kinds of things.

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176 Comments

    1. Thank you,Barb. I just find some fannel material to make some masks, can’t wait to get started. You are a special lady, that counts her blessings. Please stay well and thank you for your pattern and ideas. This shall pass!
      M.

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      1. Hello Barb, your masks are fabulous, the best fitting I’ve seen. I’m 80 yrs old & during isolating I’ve been making scrubs, bags etc. My daughter is a practice nurse working with suspected COVID-19 patients. She’s scared to go shopping with paper masks. How do I get your pattern please. I don’t have a printer & not good with technology . Thank you. Maria : 85 Dalmatia Rd. Southend on Sea, Essex SS1 2QG UK

        Reply

        1. If you can’t print then you could draft by using the grid method. Draw a 1″ grid and then work square by square to plot the shapes. See here for a video I’ll email the pattern. Maybe, if your screen can adjust you could trace it on. Best of luck

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        2. Thank you for this pattern. I tired making it and I think the steps may be out of order? How do you sew the zig zag centre seam then sew the outside edges and manage to then flip it right side out? Should you sew the zig zag after it is flipped right side out? I’m not sure how it’s supposed to work otherwise. Thank you

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    2. Some very good ideas, Barb. Beware, though, that certain vacuum cleaner bags and many hepa filters contain fiberglass and should not be used for breathing filters.

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        1. Hi Barb thanks for the pattern and ideas. I put my elastic to go around the head. The mask was more comfortable. Behind the ears rubbed and irritated my ears.

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          2. Chris….How many inches to measure the elastic to go around the head! I thank you in advance.

        2. Please STOP seeing the elastic on masks.!!!!!
          Just make the 1” wider on each side & see a side HEM CHANEL…!!! U R robbing the user from adjusting the eats loops or wearing an over the head version. Same mask but MUCH more user friendly. Then they can use anything to tie…pats cord…ribbon..hollow jelly tube..!!!
          Try it, you’ll like it.
          I’m way over 1200 masks now ..!!!!!!

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    3. Thank you for the pattern! I wear glasses, too and I’ve been searching for better patterns to fit while wearing glasses. I work in retail (we’re essential) and we are required to wear masks for the duration of our shifts (as well as if we are shopping–off the clock, of course!) The masks I’ve tried, so far, keep my glasses foggy the majority of my shift–and yes, your nose does run if you’re sweating under there! Also, I have slight breathing issues (asthma), so it’s hard to breathe… at all… I find breathing with your mouth and not your nose easier. Also, using either a tissue or a paper towel directly on your face under your mask really helps with the heat and for catching slobber and runny noses! It’s amazing all the things you don’t know are possible–only life experiences can teach you, in times like these!

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    5. Thanks for the great pattern giving it a go now!

      To my knowledge vacuum HEPA bags here never used fiberglass (it would just end up in air outside the vacuum) I work with HEPA vacs in asbestos removal in my job so the time… I do however use propylene fibers which render them harmless as a filter. Here’s a link which backs that up as well…

      https://www.vacuumcleanermarket.com/news/do-vacuum-bags-contain-fiberglass/

      Again thanks for your efforts!!!

      Stay Safe!
      Bobby

      On aside- I just cut apart a commercial HEPA bag from Nilfisk and looked at it under a 10x magnifier. There are shiny filaments in it but they are the propylene fibers easily mistaken for fiberglass- but use your own judgement, it’s your health and I’m by no means an expert

      Reply

  2. Thank you so much for sharing. I am senior citizen and a Home Health Aide. Several of my clients would feel better with a mask for protection if they have go out. This will give me the opportunity for more protection and peace of mind for my ladies.
    Be safe and thank you again.

    Reply

  3. You are amazing Barb and such an inspiration. I will try making your mask – I purchased and made your birdhouse a while back and everyone thinks that is amazing. Stay well

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  4. Barb, thank you for making this pattern available for all of us out there. Also, Barb, I wanted to say that there have been many, many times that I just wanted my mother. Sometimes, I’ve said that I wish I could just go back home again and everyone would be there. Gosh,,,that tears me up!
    Your friend, Ginene

    Reply

  5. Barb,
    Thanks for this information. I’ve got 3 men (between 25-35 yrs old) in my garden community who want to be helpful. Yesterday, I discovered a text string between the 3 of them. They were wanting to learn how to sew in order to make masks. I was so surprised and touched. I am going to forward your pattern on to them.

    I love the picture of you and your mask.

    Reply

  6. Barb,
    I just saw that you live in Hamilton, Ontario. My grandparents were from Penetanguishene and LaFontaine. My Aunt Irene lived in Hamilton. They came to northern Illinois to find work in during the Depression and ended up staying because all of my grandfather’s brothers were here and one of my grandmother’s sisters moved here. As you may know, both of those towns are small. I’ve been to Penetanguishene two or three times. Once when I was an adult. My mother used to go every summer. Of course, all of those people are gone now. Gone but not forgotten, as they used to say.

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      1. Ok I’m confused.
        I sewed the middle seam together, so now I have the shape.
        How do I turn it right sides in “like a pillow” if the middle is already sewn together??

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        2. I’m having this same problem. I go to turn it right side out and only half of the mask pulls through. I watched the video Barb posted on another comment and that person sewed the 2 layers separately rather than together so that she was able to flip it right side out. I’m going to have to improvise here by adding a third layer that isn’t attached at the centre to be able to flip everything through.

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          1. I think the confusion is that I had 3 layers, 2 sewn as one and then the inside. Only sew centre topstitch of one layer at a time, or wait until flipped. You can adapt as desired.

    2. Your a sweetheart Barb thanks so much for the easy tutorial. Shopping yesterday drove me nuts because my glasses are constantly steaming up and I feel claustrophobic and hot in them. Hopefully this cupped design will help. Cheers Kaz from Oz x

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  8. Thanks Barbara I’ve got to give these a go especially for my parents and aunt and uncle. I went to visit my parents today of course observing the distance rule etc. As soon as I saw her I started to cry coz all I wanted to do was hold her and have our usual cuddle. I’m 60 in August and it’s the first time in my life I havnt been able to give my parents a cuddle. Doesn’t matter the age Barb we all still need our mums 💜

    Reply

      1. I may have a good method for retrofitting a nose pinch strip to a mask, and a better material for making one. Could you have a look at the instructions on the web page I included. You can publish them, or include a link if you like.
        Thanks for publishing your instructions,
        Best Regards,
        Gordon Graham

        Reply

    2. Please be careful about the vacuum bags. I read that they contain glass fibers! These will irritate and damage the lungs!!! Cutting corners is awesome but everything that will work isn’t advantageous. Please be careful about what you use.

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      1. Yes, please do you own research! Information I had from a site may not be correct. I am surprised since vacuums blow air into our homes through those bags…

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        1. You can actually buy N95 inserts on Amazon and Alliexpress. I’m making them for Cleveland Clinic ICU. They say its mot necessary for the general public but the new research is devastatingly scary on how contagious this is!

          Reply