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…
Does this pattern fit men or do you have a larger size that fit men?
That’s hard to say. I have a fairly full face so it may fit a medium man… If it’s not large enough, you can print it a bit larger like 105%-110%.
Thanks so much Barb for this pattern and instructions….I wear glasses so this is great!
Barb, the pattern has clip lines on the nosepiece, did you mean to put them on the large main piece? The large main piece seems to be the piece that needs relief in order to curve around? Or am I having a brain freeze trying to sew these seams? Love, love, love the pattern, and your illustration process.
Do you mean that it needs clipping? Yes, to sew a curve the easiest you need to clip to almost the seam line to be able to flatten it. The nose piece goes in after the top seam is sewn so it can be ironed snug into the edge.
I’ve struggled to find a mask that fits my face well. Making your own pattern shaped specifically to your face was brilliant. Had to use aluminum foil though as the only tape I have is heavy duty duct tape.
Where there’s a ‘will’ there’s a way! Good going! 😷
Thank you Barb for sharing your pattern and going to so much trouble for us. I am from India and it’s hot, humid and stifling. Masks are mandatory so I will use 3 layers of cotton. And I plan to handstitch . Our govt says masks are to protect others. And N95 or those high filtering masks are for emergency workers and hospital staff. This mask is reusable. And I can sterilise it myself
I love this pattern so much! It seems to be the only mask I can tolerate. The only real change I made was using paracord and a cord stop to keep around my head, and I added pockets on the inside to place plastic canvas for even more support.
Thank you, thank you, thank you for being so generous with your talents! It feels good to see again, and your instructions were perfect for this inexperienced hobbyist.
I’m so glad! And thanks for the feedback!!!
I wonder if vinyl can be used for the center for teachers for deaf and hard of hearing community?
I have seen the ones where it is a square so I think it would act the same. My concern would be fabric choices (stiff enough to keep from collapsing) and how much it would fog up, but that would be the case with any I’d think.
Just . . . . .wow.
And Thank You!
I get a ‘kick’ out of solving problems! ‘And I love design, especially when it serves a purpose. I guess sometimes all vocations come together. Enjoy!
Does this pattern only work with knits?
No, but knits ease a bit better. The key to sewing a curve is clipping the fabric to allow flatter seam sewing. Please make your own fabric choices.
Thanks!
This is by far my favorite pattern! My husband likes the N95-Style face mask, but I like having the fabric under my chin. As I mentioned in a comment on another of your posts, when attaching the inner fabric to the interfacing, you can stitch narrow channels through which zip-ties can be inserted to add structure to the mask.
Another trick I incorporate with all patterns — when attaching the inner and outer fabrics (right sides facing), sew the top edge of the mask first, leaving a one-inch opening about 3 inches (half the length of your nose wire) from the center. Then top-stitch around that opening, with the inner and outer fabrics laid flat. Finish the bottom edge (again, right sides facing). After turning the mask right side out, top-stitch a 1/4-3/8-inch casing for the nose wire. The opening in the seam allows you to remove the nose wire prior to laundering your mask and/or replace the wire when it breaks. Thanks again for all of your creative work! ~ CA
That’s awesome! I hope that can help some of the readers. Glad to hear!
Hi Barb,
Thank you for allowing us/me to you your mask pattern. I am an essential employee and wear my fabric mask to/from work and under my droplet mask to keep my face from itching or breaking out. At least ten co-workers have asked me to make them a mask. Unfortunately, I can do that because I also have two kids at home doing school online and work full-time. I am however making several coworkers mask.
You’re right the curve is a challenge and not just on the first one. I love the masks I’ve made and choosing my own fabric.
Do you have printable/downloadable instructions, to go along with the pattern? It would be a big help.
The site has the instructions.