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Making a comfortable mask a size that is just right for you is not hard at all. The directions below will show you how to do it, step-by-step.

You will find the patterns for all three sizes of the mask below the directions. The pattern can also be found as a PDF here. You can find this entire page as a PDF here.

There are three sizes:

All of the masks can be fitted with an additional filter of your choice, as they are all double sided, with a pocket in the middle.


STEP 1: PREPARING THE CLOTH.
To make the mask you’ll need to cut out four pieces of cloth. You might want to make a template. Looking below, you can see that with just one template you can cut out all four pieces of cloth. The template, at least to me, looks like a boot.
It will be easier to sew if you iron the cloth first.

STEP 2: Sew the soles of the larger boots together, and do the same with the smaller boots as you see below. As you do this, be a little careful to make an even border of .25 inch (6 mm). To hold the pieces together as you sew, you can use pins or use a glue stick. A glue stick gives a temporary but secure hold.

Add slits along the seam you have just sewn for a smoother fit later.

STEP 3: Hem the top of each boot so that the fold points to the seam you have just sewn. You need to hem all four tops. The hems are .25 inch (6 mm).

STEP 4: Align the center seams so that the raw edges of both pieces point out. Sew the top edges of the two pieces together, starting in the middle, where the top of your nose will be.

STEP 5: To get a tighter fit when you wear the mask, you can sew about three inches (8 cm) of stiff wire into the top between the two halves of the mask. If your sewing machine can do a zigzag stitch, you’re set. Otherwise, do it by hand. You can do this step later if you wish.

STEP 6: Sew together the bottom or chin sides of the mask.

STEP 7. Turn the mask inside out.

Decide how you want to hold the mask onto your face. Your choices are elastic straps to wrap around your head or ears, a cord that you tie just once, or four straps. If you chose elastic for around your ear or head, or a cord that you tie just once, you can switch to straps later if you want to.

Step 8. Fold in the ends of the larger side of the mask so that the borders of the two patterns meet and sew the ends in place. Be sure not to seal the inner mask shut and take care to leave room for elastic or cord if you want to hold the mask on your face that way.

STEP 9. Put in cord or elastic to go around your ears or make ties to strap the mask around your head.
Ties that are 18 inches, about 60 cm, long will be fine for even the biggest head. Ties can be shoelaces, string, ribbon, or you can make your own. I often make my own by folding an inch or two of cloth several times and sewing it together, but below I've used shoelaces.

Below you see that a layer of cloth has been slipped between the inner and outer layers for a bit more protection.

Enjoy your mask!

And stay healthy.

Below are the patterns, starting with the largest. You will find the dimensions with each pattern so if you don't have a printer you can easily draw them. If you have a printer, all of these files are available in one PDF.

You can click on any pattern to open it in Flickr for an even larger view.

pattern-large-mask-a-front

pattern-large-mask-b-front

 

pattern-medium_mask_a_front

 

pattern-medium_mask_b_front

 

pattern-small-mask-both_front_outter_and_inner_layer