DIY Ultimate Fitted Face Mask
I love to design, and this pandemic has given me a new reason! You won’t believe how I make a pattern of a face. Here’s a new Ultimate DIY Fitted Face Mask & Pattern and how it came to be.
Funny face:
I hear you laughing… I was trying to laugh too. Yes, when you want to create a pattern from a 3D form what do you do?! I could not put my face in silicone soooo, tape is the next best thing. To create the ‘space’ that I wanted inside the mask I created (taped) a bunch of paper towel in from of my mouth and nose.
Next step is to cover my face with tape as close to the shape as possible. I know you are wondering if I could breathe – yes a little. But it’s all for the sake of making people a bit safer with a good mask so it was worth it! The masking tape underneath would allow this to come off a bit easier. Who needs facial waxing?! This pattern is great (thousands have downloaded) but our face does not have a centre seam. ‘And I love the challenge of forming a pattern. I have done that most of my life but never for a face! How unique the facial form is…
I have made forms of bodies and feet this way but never a face. I know it’s ‘my’ face but I think I’m pretty average… ok I have some cheeks!
Before the digital age I had taught 3D design (when the dinosaurs still roamed the earth) and we would deconstruct shapes to flatten into fold up paper structures so this is much the same since fabric is as flat as paper.
It needs to be symmetrical and looking for the flattest planes helps to where to cut it into pieces.
Marking where pieces attach & line up is the same as the notches in sewing patterns.
From these pattern pieces I added 1/4″ seam allowance to the DIY Fitted Face Mask Pattern.
The Pattern:
You can download the pattern here
Cut the Pieces for the DIY Fitted Face Mask:
Once you have printed the pattern (100%), cut the pieces as marked. This pattern makes an inside layer and outside layer; pretty identical shape but the sides are open to allow easy turning and also to make a filter pocket if you want to insert filters.
**UPDATE: I have updated the pattern file as there may have been a layer that obstructed the view if printing. Feel free to download the fixed one.
Step 1:
The hardest part of this design is the top of front nose piece. To make it easy clip the top inside (as marked on pattern) curve so that it can stretch around the top curve of the nose piece. Matching notches, sew with the large face piece on top so that you can see as you slowly sew around the curve.
Step 2:
After opening up the front (press if desired) I topstitch it towards the outside. It will keep it’s shape much better and therefore not always be touching your lips and nose.
Step 3:
The rest to make this fitted face mask is quite easy. The chin piece gets attached to the bottom matching notches and centre. You can do a bit of a ‘fit test’ to see if you need adjustments.
Step 4:
Again to keep the shape I topstitch towards the bottom. This is a polyester knit so it keeps it’s shape well. I know many suggest cotton however I wonder about the way it absorbs moisture and keeps it. Why is all workout wear not cotton? I suggest that you make your own choices of fabrics and also filter products as there is so much conflict for each material.
Step 5:
Repeat all the same with the lining fabric. In this fitted face mask I used a cotton.
Step 6:
Fold the lining ends inward (edges can be finished if desired) and only sew top edge
The there is a nose wire/metal band ironed next to the seam as I did with the Snug-nose Bridge Mask.
Fusible webbing and some strips cut from cans like sardine (top flap) or tomato work great.
Step 7:
With right side together sew the bottom seam again folding back the lining sides.
Step 8:
Turn right side out.
Carefully fold bottom and top edges.
Step 9:
I top stitch the bottom chin edge to keep it flat.
Step 10:
Fold inward and stitch the casing with straight or zigzag stitch.
Step 11:
I have started to not use elastic due to the irritation it can give and also I like to use up what I have. Cutting t-shirt fabric 3/4″ (across the knit) or so will make a nice round somewhat stretchy cord that is soft.
This fabric had so much stretch that I just used a strip as a tie.
Oh the stash of fabric remnants I have… Now I can have a mask to match each garment I had sewn prior.
This DIY Ultimate Fitted Face Mask pattern fixes some of the design challenges of the chin fit as well as the room for lips & nose. The nose bridge does not have a seam so it can be very flat incase your glasses it on top. All these make a little difference but over hours could be annoying.
When you make a mask for the first time for yourself, test the piece before you put the lining in. Adjustments can be made by slightly adjusting seam allowances as well or printing the pattern at a slightly smaller size.
I have been enjoying some sketching again as that’s how I best visualize all those ideas floating around in my crazy-artist-brain! Let me know how you like your mask. Stay safe and we all look forward to the future…
Fabulous and so generous of your creativity and thought processes. Keep safe.
Thank you for offering your patter for use. I am very interested to try it as I have a nephew with asthma who hasn’t been able to wear other masks yet. Thank you for the idea that tape could help determine a precise fit. That is the #1 challenge as a very novice sewer. The download doesn’t work. Is there something more I need to do to get the download? I don’t think it is an Adobe issue. Thank you in advance for your help.
Emailed it!
Great job ! Thanks for sharing.
This pattern looks like a well fitting mask !
I was able to download the pattern, but not seeing a way to print the instructions.
Did I miss a link ?
Thanks in advance for any assistance you can provide.
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I am very interested in trying your Ultimate Fitting Face Mask pattern but cannot download the pattern. I do not know what i am doing wrong and would appreciate assistance. Is it perhaps because i had not donated to your site yet?
done
Hi Barb, I’m the one WHO WS LOOKING for a pintted pattern for your mask. so finally got off my duff ad bought a print &ink, now I can’t print the pattern, message comes up, convert pdf file nd does nohing I’m lost to say th least LOL, he n wesome day
If your computer won’t print the PDF you may need Adobe Acrobat Reader. You should not have to convert the PDF at all to print as that’s the standard format for best printing. Maybe search what the message says. I know the first version of the pattern had an extra layer, Download it again and see if it matters. I have updated it.
Bravo Barb! Your latest mask is so well-designed and drawn ( as Brenda mentions :)) )
Kudos on sharing-All your great work to help us be well and to safely-relate….
Kind and HeARTy Thanks!
Awe Thanks! You must be chuckling at my tape-covered face! You know I love designing 3 dimensional! I hope it helps!
Hi there, love your face mask! I’m not very good at sewing and I’m wondering do you sell them already made? If so I am very interested!
I’m so sorry, I just do not have the time to deal with shipping across borders, it’s really not worth it to most. Check local sewing centres and maybe suggest a pattern. Stay safe!
I sew and sell stuff. If i’m understanding Barb’s pattern credit, I can use her pattern and make you a mask so long as I don’t claim to have made the pattern my self. Email me if you want a mask.
Email me, Barb, if you have an issue with me using your pattern.
Thank you both.
Sure, Make them! Just don’t sell/distribute the pattern. Any credit would be appreciated. You may also consider sizing, as someone said it felt like it was a man’s size. I guess I have a pretty full face 🤪
And I’m very lazy … I took the smallest baby’s cap, ripped off the visor, edged and sewed elastic bands
I wish you would sell these, the directions look like they are above my skill level.
It isn’t that bad, after the first one you get the hang if it. It’s all about the clipping to get around the curve…. Good luck
ok so I made this mask the first time and did an great job but it was too big. So then I tried your other mask that is similar to this one, I resized the pattern and made the mask no problems. Then I came back to this pattern, resized and I have been having a heck of a time trying to get around that curve. After fighting it for a few days now, I came back to your website to reread the instructions and see what it is that I was doing wrong. Nothing, I followed instructions to the T. So I was sitting here dumbfounded and looked up at your picture of you pinning the curve together and I saw my problem. On the pattern it instructs to clip the nose center, but in the picture it shows that you have actually clipped the face front. Low and behold I tired it that way and IT WORKED!! I f don’t know if anyone else has pointed this out, but what a difference it made. I am very stubborn and I love the other face mask pattern, it’s the only style of mask that I wear. I wear glasses and this is the ONLY pattern I have found so far that actually will not fog my glasses! (I’ve only tried maybe 20 other patterns!) THANK YOU!!!
Oh, I can well imagine not clipping was an issue. I’ll take a look. I’m sorry you had an issue, but glad you persevered! I bet you’ll remember that!
Sorry, I couldn’t find the patterns.
Patterns are linked in the post and also on this page
Gorgeous and so well designed! Are you perhaps selling these? 👍
No sorry, I do not sell. I put all my energy to the site and I also teach post secondary. I’m sure there are some local people making masks.
This is fantastic Thank you! We’re going to give this a try. I need something fitted for my larger head and to combat my glasses from constantly fogging. Question – Where exactly is the pocket for filters?
The sides are open next to where the straps are attached. Glad to help