Face masks have become an essential accessory during the COVID-19 pandemic. With recommendations from health organizations to wear a face covering in public to help slow the spread of the virus, demand for disposable and reusable masks has skyrocketed. Knowing how to sew a simple face mask yourself allows you to contribute to relieving the shortage, while also providing masks for yourself and loved ones. With some basic sewing skills and supplies, you can make fabric face masks at home.

Supplies Needed

Sewing your own face mask is a relatively easy DIY project as long as you have the proper materials on-hand. Here’s what you’ll need:

Fabric: Use tightly woven cotton fabric, such as quilting cotton or cotton sheets. T-shirt material can work too. You want a fabric that can be washed and reused. Make sure it’s breathable. Avoid stretchy fabrics.
Elastic bands or fabric ties: For securing the masks around your ears/head. Elastic bands work best, but you can make fabric ties from cotton fabric strips or t-shirt material.
Sewing machine and thread: Don’t worry if you only have a basic machine. You don’t need anything fancy for this project.
Sewing scissors: For cutting fabric and thread.
Pins: For securing the fabric pieces together before sewing.
Measuring tape or ruler: For measuring fabric to cut to size.
Iron: For pressing seams and hemming edges. An iron gives the mask a more polished look.

Pattern and Cutting Fabric

There are lots of face mask patterns available online that you can print out, trace, and use for cutting your fabric. Choose one that fits your sewing skill level. Here are some options with instructions:

CDC mask pattern: CDC.gov face mask pattern – This is a simple rectangle pleated style mask.
Fitted mask: Masks4All face mask pattern – Includes sizing for small, medium, and large for a better fitted shape.
Contoured face mask: CraftPassion face mask pattern – Shaped to contour the nose and chin.

Print the pattern and cut it out. Pin the pattern piece to your fabric and carefully cut around it. Be sure to cut 2 pieces of fabric for the front and back of the mask. If your pattern doesn’t include seam allowance, add 1/4″ – 1/2″ around the edges before cutting your fabric.

Some quick tips when cutting fabric:

Use freshly washed 100% cotton fabric. Pre-wash and dry with high heat.
Cut fabric with the grain, making sure the edges don’t curl.
Place pins perpendicular to the edges to hold the paper pattern piece securely while cutting.
Don’t pull or stretch the fabric as you cut.
Change your rotary blade often for smooth cuts.
Layer pieces and cut through both layers at once.

Sew the Face Mask

Follow your pattern guide for specific sewing instructions. Here are some general steps:

1. Transfer markings

Use a fabric marker to transfer any pattern markings, dots, pleats, etc. to the wrong side of the fabric. This includes centering and spacing for elastic or ties.

2. Stay stitch edges

On each fabric piece, sew a stay stitch 1/8″ from the edges that will be seamed together. This keeps the edges from stretching as you sew.

3. Sew darts (if needed)

If the pattern calls for darts to shape the mask, sew them now. Backstitch at the dart point for reinforcement.

4. Join inner and outer fabric

Place the 2 fabric pieces right sides together, matching the edges. Pin the layers together. Sew the front to the back piece with a 1/2″ seam allowance and backstitch at each end.

5. Box corners

For a smoother shape, box stitch the corners. Fold the corner diagonally with right sides together. Sew across the folded edge. Trim seam allowance. Turn right side out. Repeat for all 4 corners.

6. Topstitch edge

For a clean finish, topstitch close to the edge around the entire mask. This also helps the seam allowances lay flat.

7. Add elastic/ties

Pin then sew the elastic bands or fabric ties to the side seams for securing the mask. Check the pattern for exact placement. Be sure not to twist elastic.

8. Finish edges (optional)

For fabric that frays, finish the inner seams by zig-zag stitching, serging, or using seam sealant. Or turn edges 1/4” and topstitch.

Once constructed, wash the reusable fabric mask before first use on the warmest setting allowed for the fabric. This pre-shrinks the fabric for a better fit. Then press with an iron on a cotton setting. Now the mask is ready to wear!

Sewing Tips for Best Fit

Follow these tips as you sew for a comfortable, well-fitting face mask:

Take measurements of the person wearing the mask to customize sizing as needed.
Choose tightly woven, washable fabric for effectiveness and reuse.
Cut fabric on grain for minimal pulling or distortion.
Mark pleats and darts accurately on the wrong side before sewing.
Sew inner seam first, then attach ties or elastic for perfect placement.
Use zigzag stitching on seams and elastic to allow stretching.
Box stitched corners prevent collapsing and keep shape.
Topstitching makes seams lay flat and look neatly finished.
Allow room in sizing for shrinking after washing/drying fabric.
Wash and press mask before first wear for ideal shape and fit.

Following the pattern guide closely coupled with these useful tips will result in a comfortable, reusable fabric face mask you can feel good about wearing.

Troubleshooting Mask Issues

Even if you carefully follow the sewing steps, you may end up with a mask that fits poorly or feels uncomfortable. Here are some common problems and solutions:

Mask is too tight across nose and mouth: Remeasure width, increase seam allowance, and recut front/back fabric for more coverage. Adjust position of darts or pleats for more room.

Mask rubs or chafes behind ears: Check that elastic isn’t twisted. Use soft elastic or add fabric tape extensions to wrap elastic ends for cushion.

Mask is too loose: Take in side seams or reposition elastic for snugger fit. Use smaller elastic or fabric ties to secure tighter.

Mask fogs glasses: Move elastic away from ears or use fabric tie version to eliminate gap near nose. Use wire sewn into top edge to pinch mask around nose bridge.

Mask irritates skin: Try smoother fabric like cotton broadcloth. Bind edges to prevent irritation. Wash and dry mask several times to soften fabric before wearing.

Mask slips down face: Shorten elastic or fabric ties so they pull mask tighter to head. Use cord locks or knots to adjust tension and prevent slipping.

Breathing is difficult: Change fabric to lightweight cotton for easier air flow. Make sure mask isn’t too tight across nose and mouth.

Following pattern adjustments, you can easily alter the mask for maximum comfort while maintaining proper coverage and effectiveness.

Mask Styles and Variations

Once you get the hang of sewing a basic face mask, you can get creative with fabrics and customize the look. Here are some easy variations:

Add a pocket: Sew a pocket on the outer mask layer to hold a disposable filter for extra filtration. Use lightweight interfacing to keep the pocket open.

Make a contoured mask: Sew darts or use a shaped pattern for a contoured mask that hugs the nose and chin.

Try other fabrics: Use cotton blends, denim, or knit fabric for more options. Stretchy fabrics work well for fitted masks.

Make reversible masks: Select two coordinated cotton prints or fabrics to sew a reversible mask.

Use directional fabric: Play with fabric direction, like making ties with vertical stripes.

Add ties: Sew 4 fabric ties instead of elastic for a tie mask that secures at the back of the head.

Create pleats: A pleated style mask provides more surface area for breathing ease.

Topstitch designs: Use a contrasting thread color to topstitch shapes like hearts or your name on the mask exterior.

Make kid sizes: Scale down pattern dimensions to sew masks that fit younger children. Use fun fabrics!

Mix and match elements like pockets, applique, trims, and monograms to design unique fabric masks. Accessorize them to match your personality or wardrobe.

Mask Care and Use Tips

Proper care and handling of your homemade fabric face mask is essential:

Adjust ties/elastic for snug fit over nose and under chin with no gaps at cheeks or sides.
Use hand ties behind head rather than elastic for less pressure on ears.
Wash regularly, especially after going out in public. Use hot water and dry fully on hot cycle.
Wash before first use to pre-shrink fabric for better fit.
Handle only by ties when putting on and taking off. Avoid touching front panel.
Store carefully between uses. Do not distort shape of mask. Keep in clean bag.
Do not share your mask with others. Make each family member their own.
Rotate masks so you have clean backups ready. Have at least two per person.
Use with other measures like handwashing, social distancing, and avoiding touching the face.

Fabric masks are not medical-grade protection, but following health guidelines for maximizing their use helps slow the spread of COVID-19.

How to Sew a Basic Face Mask: Final Tips

Use tightly woven cotton fabric and elastic for comfort and durability.
Precisely cut fabric pieces on grain for minimal distortion.
Mark pleats and darts on wrong side of fabric before sewing.
Allow room in sizing for shrinking after washing and drying.
Box stitch corners for a smoother shape that holds.
Topstitch trimmed edges for a clean, polished finish.
Check fit and make any adjustments before first wear.
Handle only by ties or bands when putting on and taking off.
Wash and dry fabric masks on hot setting between each public use.
Have at least 2 masks per person to allow for laundering rotation.
Combine proper mask use with other hygiene and social distancing measures.

With some basic skills and supplies, you can sew fabric face masks at home to help meet the ongoing demand during pandemic times. Experiment with fun fabrics and customize your masks to make them comfortable and uniquely your own!

Frequently Asked Questions about Sewing Fabric Face Masks

Hand sewing reusable fabric face masks is an easy and rewarding DIY project. As homemade masks gain popularity amid global PPE shortages, common questions arise on mask designs, performance, materials, and uses. Here are answers to the most frequently asked questions about sewing your own masks:

How does a fabric mask protect against coronavirus?

Fabric masks are not medical-grade PPE like N95 respirators. However, well-fitted homemade masks, worn correctly over the nose and mouth, provide two key protections: 1) the fabric barrier helps block larger expelled respiratory droplets from spreading, and 2) they contain the wearer’s coughs and sneezes to prevent emitting as many infectious particles. Less virus exposure lowers disease transmission risk.

What is the best fabric for making masks?

Choose tightly woven 100% cotton fabric with a high thread count, like quilting cotton or cotton sheets. Tight weaves and higher thread counts create smaller holes that block more droplets. Breathable cotton is durable with some stretch for comfort.

What about using an old cotton t-shirt?

In a pinch, an old 100% cotton t-shirt can be used to sew a mask, but the knit fabric’s stretch and weave may have bigger pores than quilting cotton. Use a double layer with pleats for improved filtration.

How do you properly wear a cloth mask?

Cover your nose and mouth fully. Secure ties or elastic snugly against sides of face and behind head. Adjust for comfortable fit that keeps mask in place without gaps. Do not touch the front of the mask while wearing it. Wash hands immediately before and after mask removal.

Can I make my own mask pattern?

Yes, you can draft a simple face mask pattern based on measurements. Add 1/2″ seam allowances to finished dimensions. A basic pleated rectangular mask is about 9″ x 6″. Contoured and fitted styles may require more shaping. Test and tweak the pattern to fit before cutting fabric.

What is the best way to sterilize homemade masks?

Washing in hot, soapy water is recommended after each use. Dry fully on the hottest setting safe for the fabric. Steam ironing provides additional disinfection between washes. Do not attempt to sterilize masks with chemical disinfectants.

How can I stop my glasses from fogging up?

Fogging occurs when exhaled breath escapes the mask near the nose. Options to minimize fogging include molding the top edge wire to the nose bridge, moving the elastic knots to the back of the head, or using a mask fitted for glasses wearers.

Can I layer a disposable mask under a cloth mask?

Yes, wearing a disposable mask underneath provides added filtration. Disposable masks alone are hard to fit tightly, whereas cloth masks seal better to the face. Use the disposable as a replaceable filter insert.

What is the best way to sew curves and corners?

Trim seam allowances on curved edges to reduce bulk. At corners, box stitch for smoother seams that lay flat. Mark darts and pleats first, then stitch carefully. Press all seams after sewing for crisp corners and edges.

Should young children wear cloth masks?

The CDC recommends children over the age of 2 wear face masks in public if tolerated. Make kid sizes to fit smaller faces snugly. Supervise use, removing masks if a child experience breathing difficulties or interferes with their breathing.

How can I adjust the fit if my mask is too loose?

First, adjust the ear elastic, ties, or headbands for a snugger fit against the sides of the face. Replace elastics with smaller sizes if needed. Take in side seams. Close gaps by crossing ties behind the head instead of at the ears.

Is it safe to use a sewing machine and iron while making masks?

Yes, follow proper precautions. Wear a mask while sewing. Don’t touch your face. Clean machine and iron surfaces thoroughly afterwards. Consider steam ironing instead of fabric softener for sanitizing. Wash all masks before first use.

Hand sewing reusable masks is a practical way to create a supply of comfortable face coverings. Following mask-wearing protocols in addition to social distancing and hygiene offers optimal protection. With some creativity and care, fabric masks are a crafty way to stay safe.

Tips for Proper Fabric Mask Use and Care

Fabric face masks have emerged as a ubiquitous accessory during the pandemic era. While not medical-grade personal protective equipment (PPE), homemade cloth masks worn properly provide meaningful benefits in slowing disease transmission in communities. Follow these handy care and use tips to get the most out of your fabric face masks:

Putting On Your Mask Correctly

Clean hands first with soap and water before handling mask.
Check condition of mask, looking for tears or damage.
Face any pleats outward while donning.
Secure ties or elastic comfortably but snugly against sides of face.
Adjust metal nose piece (if there is one) to fit bridge of nose.
Make sure mask covers nose, mouth, and chin completely.
Avoid touching mask surface during use. Re-adjust by handles only.

Taking Off Your Mask Safely

Avoid handling front panel by grasping ties or elastic only.
Do not let mask dangle from one ear or around chin/neck.
Remove by head straps for masks with no ear loops.
Fold inward with outer surface contained.
Immediately wash hands after mask removal.
Wash mask before reusing, storing carefully between uses.

Storing Masks Effectively

Keep used masks in resealable plastic bags until laundering.
Store freshly cleaned masks in breathable bags, like paper or mesh.
Avoid crushing or deforming mask shape when not in use.
Designate hooks or bins for separate storage of soiled vs. clean masks.
Use clear bins or bags to easily identify personal masks.
Keep masks in a specific spot, like by the front door, for easy access when going out.

Keeping Masks Clean

Machine wash frequently in hot water with regular detergent.
Tumble dry on high heat setting to sanitize further.
Press with warm iron for crisp shape between washes.
Hand wash gently if machine washing not possible, rinsing thoroughly.
Avoid bleach or fabric softener to prevent irritation or damage.
Pre-wash fabric before sewing for maximum shrinkage and best fit.

When to Discard a Fabric Mask

If mask becomes torn, damaged or misshapen.
If ties, straps or nose wire are broken and cannot be repaired.
If mask becomes too loose in fit despite adjusting straps.
If stains or odors persist after repeated laundering.