DIY N95-Style Face Mask Pattern
After having my mask keep sticking to my face I knew there was a better way… Welcome the next in my series; the DIY N95-Style Face Mask Pattern. It closely mimics and holds shape as the N95’s.
Am I a mask expert? No, but I am one of those particular people. When I see something that is not functioning well I want to make it better. It’s how I have been pretty well as long as I can remember. The curve of the Ultimate Face Mask also scared some sewers so this only has a point.
What fabric?
I have been going through my stash of fabric (trust me, it’s a pretty extensive collection) and holding it up to the light (to see the holes) and over my mouth to test breathability. I question the high thread count cotton as it’s so difficult to breathe through!
I saw some advertising of using faux ‘Shammy’ fabric. These brand-name products are a non-woven felt like fibre made of rayon and polypropylene. It’s quite thick as it can hold a lot of water. Since I do a lot of dyeing and sewing I have to know my ‘fibres’. Rayon is a natural fibre made of wood products, absorbent as well. You may have a blouse that is quite comfortable to wear and also very silky soft; it’s probably Rayon. Viscose is almost the same as well. Craft felt is often only polyester and much thinner. There are some wool felts but I am not sure of the comfort level.
I was told that cotton can take the moisture from the covid partical where as polyester does not. Odd, as any professional N95 masks have no cotton in them. (Do your research)
These shammy’s (like Sham-wow) are machine washable and some even bleachable. I love felt type of fabric since it does not fray at edges, can be sewn so easily and hold shape well. I have used industrial felt for purses and containers often.
Back to Designing:
My N95 mask (from concreting) is sturdy and stiff. I like that. It stays OFF the face and he round outer edge rests pretty well around a wide variety of face shapes. So, from that shape I took my inspiration.
I teach a technical type of drawing so I understand form quite well. I love the challenge of working with forms (I guess that’s why I like concrete) and constructing or deconstructing them.
Fabric is flat and then needs to fit a rounded form. How ‘cool’ is pattern making?! I have never had to ‘fit’ faces; usually just my ‘bumps and lumps’! Round becomes flat… awesome.
I have fond memories of my mother working as a milliner, over a wooden head form making exquisite hats for some very sophisticated ‘dames’. She would cut and sew and steam and get such amazing shapes. It’s been over 50 years but it must have made an important impression. Look how similar to the N95 the shape is!
I have made a pattern for you; download it here:
The DIY N95-Style Mask Pattern:
- Can be left unlined
- Bias edge finish, no turning
- Optional extra stiffening insert
- Very flat Metal Nose Piece
- Keeps form & shape
- Innovative 2 piece Pattern
- Adjustable tie casings
Print the Pattern at 100% (note folded piece) and cut the pieces. I like to trace it on the felt with a fine marker as then I can cut it more accurately.
As with the ‘Snug-nose Mask Pattern’ I love using the iron-in nose strips. You can put it in place before assembly if not lining or between the layers if lined. For the unlined version cover the inside with some folded bias fabric. Keep it .25″ from the edge.
The Scary ‘Point’:
The nose section is sewn in 2 stages. Match the dots after clipping to the dot.
The stitching starts at the ‘dot’ and continues to the edge. Clipping around the face curve helps sewing the curved seam.
Not so scary… 1/4″ seams.
After the first half, open at centre and match the other side and sew to the matched dots again.
It is like 2 seams that meet at the dot, and clipping is vital. If, it is too complicated, feel free to add seam allowance at the centre and then treat as separate seams (but still match dots)
The bottom centre seam is much like a dart; and ends curving into the edge at the dot. Trust me, after one, it’s super easy.
Looks odd, but has great shape already.
Since this felt like ‘shammy’ is a felt, it does not fray and can be trimmed very close. I love that about working with felt.
Turned right side out it holds shape already, without any pressing at all.
See the unlined and lined option. Rayon is not uncomfortable and this mask pattern does not really lay on the face, so I actually like it in one layer… but suit yourself. (skip down to the edging if no lining desired)
Lining Optional:
If desire you can also line this N95-Style Face Mask Pattern. Repeat the same steps as for the outside with a cotton fabric. Be aware of breathability. I like to top stitch to keep seams as flat as possible and less ironing.
Shape Stiffener:
To make a mask not be able to keep collapsing you can also add some ‘boning’ as they call it in the fashion industry. Remember the corsets? To add a flexible but shape hugging strip ‘zip ties’ can be easily cut and inserted into an added casing.
Determine where you would like the strip to follow across, higher near the nose is better as that is where the space in the mask is most comfortable. Cut a 3/4″ strip of fabric on the bias (45˚ angle) and pin across.
Stitch across on the wrong side of lining.
Sew the casing by leaving a space wide enough for the zip-tie.
When using a lining the metal nose piece is ironed into place between the layers. (make sure to keep at least 1/4″ from edge)
Stay stitch lining to outside, wrong sides together.
Edge Finishing:
As an edge finishing, the outside edge has a bias strip applied. You can use purchased bias band or easily make your own.
I like to stitch the outside last so I sew the first seam from the wrong side.
Fold over to the right side and topstitch the bias band only on top and bottom edges. (side casings will be folded)
Sew the casing line on one side. Insert the zip-tie and cut to length taking in account of the fold for the casing.
Sew the other casing line. This will keep the zip tie in the channel.
As an alternative to double folded bias, you can ‘cheat’ by only folding back and leaving the raw bias edge on the inside. Bias edges tend not to fray. The seams are also cut very close so there is no large seam to bother your face.
Tie one on:
Rather than elastic, (which is getting scarce) I love to use t-shirt strips! If you use a t-shirt with some lycra it has a great stretch, and is soft in the ears. 3/4″ wide or so works well and a ‘Pony Bead’ can act as a toggle.
So, what do you think of this N95-Style Face Mask Pattern? It holds shape nicely, stays off my skin, breathes well, and is blue. But you be the judge… I have a few patterns to offer. We all don’t like the same.
But above all, make good decisions and practice good cleanliness. I hope to just help keep you safe and comfortable one mask at a time.
Barb,
Thanks for all the mask tutorials and patterns. You are obviously working hard to perfect the shape and breathability. Let’s hope we don’t need them for very long!
Yes! But if we do… then why not have good ones?! 🤞🏻🤷🏻♀️
I have spent 1.5 hours trying to find the pattern for the mask for glasses wearer. I am willing to pay for it but it is absolutely no where to be found. I am so disappointed! Please, Please send me the pattern! If I need to buy it, send me the link to pay for it! And the last thing I need is a PDF Donloader.
Adobe Acrobat reader is free. I’ll email the pattern… Stay safe – breathe 😷
Hi Barb thank you for your good work and so very kind heart to share this pattern with us all. I wasn’t able to download, so I drew up a grid and sketched out the pattern. I am going to work on cutting and sewing it tomorrow. It is late of night here in Gold Coast Queensland Australia. We in this state have had only 3 carona cases and no deaths. The total deaths for Australia has only reached low 300’s. Not sure of the actual count at present. Our borders closed very early and it seems to have been the best action, so far. I haven’t heard any news of Canada even though we have family their they are not close. I send my best wishes to you and your family to stay safe . Narelle Jones
Good job! I hope you like it! Best wishes from afar!!
How can I make bigger for Men or Smaller for child or teenager and fat or skinny face ?
If you compare the size to the original by measuring – Divide the desired size by the original = __% to which to print pattern. I hope that makes sense, some simple math.
Thank you for the fabulous patterns. I can’t wait to try them out.
I have been using Fabritac glue by Beacon instead of sewing . Works fantastic. The COVID pathogens are smaller than a human hair and can invade through sewing needle holes. The glue can be washed and so strong you would have tear the fabric before it would come apart. I have used on outdoor awnings and it has never separated even in highest wind.
Clip the curve around the nose of Main pattern piece( top portion of mask). run a thin bead of glue and fold back edges of seam allowance to glue down. Lay this glued piece over the 1/4” seam allowance of nose piece. This center part of mask is most important to keep free of stitching holes. The rest of the mask can be stitched or glued to complete. The glue adds a stiffening affect to the mask center which holds the mask away from the mouth.
Wow, interesting glue! I must give it a try! Thanks and stay safe!!!
But is the glue safe to breath?
What glue do you mean?
yes – ones that stand away from your face are so much more comfortable! nice one.
You are a genius to me! I also feel you should be proud of yourself in creating these patterns, that are outlined so well. I can’t thank you enough.
Haha, thanks! Glad to help in a small way.
Have you considered making these and selling them to those of us who are unable to even thread a bobbin….it would be a great service
Well, there are not enough hours in my days as I also teach. Making this available is the best I can do. I know from shipping the odd item that the shipping costs often make it not worth buying as I’m in Canada. Check local buy/sell sites as many home seamstresses are sewing masks and could possibly make a custom one. Best of luck…
Complimenti sei bravissima e grazie per questa condivisione. Saluti dall’Italia
How does this hold up in the wash? air dry? shrink?
I washed mine before using and can’t say if it shrunk as I did not notice, and it was easy to iron, even though it hardly wrinkled. The ones that are Shamwow imitations are probably better than the wizcloth as it’s really thin.
Yes, I had washed mine and did not notice a size change as it was pretty well the same thickness, and it can be ironed. They suggest air dry. Shamwow does state that it is bleachable. The wizcloth is really too thin but shows the fibre content.
Is It the orange non shamwow brands that are the better ones to use? The original German shammies you’re talking about? The material would need to be chemical free.
This is an amazing pattern but can’t download the actual pattern no matter what link I follow. I just keep getting ad links that want to make changes to my computer and a request to support your blog. How do I download your free mask pattern?
For some reason the odd one has an issue. I think it’s a device/browser problem. I email them when I get contacted. I sent it…😷
hi Barb love your face mask patterns The only problem I have is I cannot download them I usually don’t have a problem downloading patterns but cannot download these. I WOULD GREATLY APPRECIATE IT IF YOU COULD email the pattern to me.
Thank you
What device are you on? I do check that it works and mine do. I’ll email it…
I agree with you. This might help somebody.
I tried with Opera and it appeared to download but it was only viewable on screen, not printable (only ‘printed’ blank pages).
Microsoft Edge had no problem whatsoever. I tried both concurrently out of curiosity, with Edge working but Opera still doing the same.
Hi, Could this be made with a pouch to hold the PM 2.5 filter ? Thinking something as nice as this should have full N95 filtration capabilities !
There’s always the option to leave an opening next to the casing. It would take a bit to slide in but better there than bottom I believe. Just hope the lining doesn’t then bulge at face. Maybe then add stiffener strip. Good Luck
Hi. I can’t download the pattern either. Just brings up your site again. This looks like a great mask that won’t be smack up against your face.. I hope that your pattern is in black and white. I don’t have a color cartridge and if the pattern is in blue it won’t print at all. Thanks!!
Done
Thank you for all your hard work. I made a mask yesterday and the family all like the shaping. They especially like the zip tie across the face.
Problem I encountered-My print out was correct at 1” Squares. The seam lines of the nose area matching the opening on the main did not match. I walked it several times. I had to lengthen the seam line on the main piece to get it to match.
I’m going to print at 110% today to scale up for my husband. I’ll check the seam lines on that print out.
Also. I sewed the main and lining together on the upper and lower edges and turned them right sides out at the casing opening. I edge stitched at a scant 1/8” along the top and bottom. No bias binding needed.
Nose wire- a flat twist tie from bags of coffee worked perfect. I folded the ends under 1/2”.
Fabric- polyester fabric type of shopping bag. Researched by Maker Mask website. I used the straps for the channeling for the twist tie.
Thank you again.
Thanks, I’l look into it. Might be that some fabric will ‘give’ easier than others…