This is the link to the tutorial on my blog where you can find a sewing pattern for the fabric face mask Cut 2 front pieces of the mask with good fabric scissors.
Cut also 2 pieces of lining. (Remember, lining pieces should be a bit smaller than the main pieces).
You have to cut out 2 mirrored pieces, left and right. Their shape is exactly the same but they are not identical. They are cut in opposite directions because they are symmetrical mirror images of each other.
Step 5
Now we are going to sew darts.
Cut the darts on the paper pattern pieces. Don’t cut them on fabric pieces of course.
Draw darts on fabric pieces using a fabric marker. We have 2 front pieces of the mask and 2 lining pieces. All of them have darts.
Fold each piece in half and pin preparing the darts for stitching.
Sew all the darts. Start sewing a dart from the edge of the pattern to the center. Backstitch in the beginning but don’t backstitch in the end. Tie the threads at the end of the dart and cut them. Cut also the other thread tails.
Step 6.
Baste 2 main pieces of the mask right sides together (by hand sewing), seam allowances are ⅜” (or 1 cm) and check how it fits around the nose. It’s very easy to do. After that make necessary adjustments to the pattern. The mask shouldn’t be loose around the nose.
I noticed that for the correct fit the side seams should be a bit smaller than your ears. If the sides (in the finished mask) are bigger than the ears the mask will not sit close to your face at the sides.
If you need to make the mask smaller for a child remember that the pattern has ⅜” seam allowances up and down and at the sides, so cut accordingly.
After you are done with fitting pin 2 front pieces and 2 lining pieces right sides together like you see in the video. Stitch the middle seams and press seam allowances open on the front piece and on the lining.
Step 7
I see that the surgical masks have a thin metal insert for better fitting around the nose which it increases its effectiveness in protecting against the penetration of microorganisms. So I took one from a used mask. You can do the same. It provides a snug fit to the nose and you can change the area of contact depending on the size of the nose.
Make a small casing for the metal nose insert. I used a piece of ribbon for this.
Pin it to the lining piece at the distance a little bit more than ⅜” (1cm) from the fabric edge and stitch. Make two seams to form a casing for inserting the metal piece.
You have to attach the ribbon to the right side of the lining piece which will cover your nose.
Step 8.
Pin the front piece and the lining right sides together. Make sure the ribbon insert for the nose is placed up if you have a special pattern on your fabric. For example, I didn’t want my Unicorns upside down on my mask.
Make only 2 seams: one up and one down the mask. LEAVE ABOUT 1 INCH (or 2 - 2.5 CM) WITHOUT STITCHES ON ALL SIDES. You will see later why.
ALSO LEAVE OPEN around 2 INCHES (or 5 CM) IN THE BOTTOM SEAM FOR TURNING THE MASK RIGHT SIDE OUT.
Step 9
Ok, you see that I made 2 seams up and down and I have 1 inch not stitched on all sides and I also have the opening for turning the mask right side out.
These seams are not straight, they are curved so I have to make small cuts close to the seams so when I turn the mask right side out there will be no pulling in the seams.
Now we need to stitch the sides. But I want to make casings for elastic loops on both sides.
So for this fold the seam allowances as in the video (image below) and make the side seams.
Step 10
Cut the seam allowances at the side seams close to stitches.
Turn the mask right side out. Smooth every corner. Baste the mask around all edges and press with an iron.
Topstitch the bottom edge only (you will need to close the opening). I didn’t want to topstitch the upper edge because there is the ribbon insert.
Remove the basting thread.
Step 11.
So, we made casings for the elastic loops.
Now we need to insert elastic for the mask. Elastic loops make the process of putting the mask on as simple as possible.
Elastic has to be very thin and soft so it doesn’t make any discomfort for the ears.
I have this very nice elastic, it’s silver and would look great with this fabric. But I see it’s a little bit too hard so I decided to go with less fancy regular elastic which is softer.
Insert the elastic using a safety pin. Measure the elastic around your ears so the mask sits comfortably - not very tight, so it doesn’t pull your ears, but not very loose also. Make a knot when you are done and pull the knot inside the mask so it’s not visible.
Step 12.
The last step is fixing the elastic inside the mask so the sides stay flat around the face. I just made big zigzag stitches at the sides. After you are done insert the metal piece for the nose.
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