Simple Sewing Tutorial: How to Make a Fabric Face Mask

***This post was updated on 10.06.2020***

There’s no avoiding it these days. Coronavirus.

It’s in the news. It’s all over social media. It’s all anybody seems to be talking about. Perhaps you have been home-schooling the kids and juggling to work from home yourself. And when you do go outside, there are a couple of things that grab your attention.

One: the social distancing thing. You notice that people are trying their best to give every other person around them extra space. That shopping queue looks so verrrry long, but actually it’s just the space between each human.

Two: the face covering thing. Here and there and in ever increasing numbers, you see people wearing face masks. Some wear a simple scarf or bandanna, wrapped around their face and nose. Some wear what looks like professional, fancy blue, medical one. While others cover their face with a mask that would almost make Darth Vader jealous.

Whatever it is that you have noticed around you and in the media, it’s new, it’s strange, and perhaps even a little disconcerting.

For the first few weeks of Coronavirus spreading here in Germany, I held off from sewing a face mask. Would I need it? Would I have to wear it? Would it even help?

But I noticed more and more popping up on people’s faces everywhere I went. And the World Health Organisation altered their original recommendations about wearing face masks. And then there was talk in the media of making face masks compulsory as people gradually return to “real life” after lockdown.

***Updated*** From 27th April, 2020 face masks DID become compulsory on public transport across Germany. As businesses have begun opening up again, in many states it is also compulsory in shops, restaurants, hairdressers, health providers, post offices etc.

Decision? Time to make myself and my family face masks!!!

I have had SO many people ask me how I made them, I can’t NOT share this sewing project with you. I will walk you though step by step with plenty of easy-to-follow photos so you can sew a fantastic, fabric, face mask yourself.

You’ll also learn some simple tips and tricks to help get you through sewing a face mask (or 2… or 5… or 10…).

Let me start off by saying, though I think you are smart enough to know it already: This is NOT a medical-grade face mask. If you are working in a hospital setting with very ill people, this may not be the mask for you. If you are caring for someone outside of a hospital setting, this mask will help prevent you from transferring any of your own germs to them. If you are living somewhere that requires you to wear a mask on public transport or in the workplace, this is the one for you. If you just want some piece of mind to add to your hygiene habits when you step outside your front door, this DIY face mask is ideal.

I also need to add: This mask is not my own design. I found this project online at Nähtalente. Like I said, I had a lot of people asking me to share the pattern. But… the instructions are in German, which leaves all the non-German speakers a little lost 😉.

There are endless instructions to be found online these days and many of them ultimately look the same. I just liked this one and it’s the one I have been asked by numerous people to share. So…

BIG thanks to @naehtalente for the face mask design! I am not selling these masks. If you are thinking about selling masks made with this pattern, you should contact Nähtalente directly😉)

I have assembled the instructions here for you using own my words- in English– along with a few tips and a couple of tweaks for you right here.

And finally, do you want to know what’s also great about this face mask sewing project? The pattern is available in 3 sizes, so you can get the whole family covered!

Let’s get started!

DIY Fabric Face Mask Tutorial

What You’ll Need

Fabric for the outer layer of the mask- cotton, colour and pattern of your choosing

Fabric for the inner layer of the mask- cotton, colour and pattern of your choosing

Elastic- approximately 5mm wide

Optional!!- Craft wire, pipe cleaners, twist ties (from freezer bags etc) or similar for nose wire, approximately 10cm long (See notes below!)

Scissors, measuring tape, thread, pins, sewing machine

Important Note about Fabric: You’ll want to choose cotton fabric that you can easily breathe through. Seriously! Hold a double layer of your fabric over your mouth and nose to test whether you can still breathe comfortably. You also need to be able to wash the fabric clean at high temperatures. Popular fabric choices include plain cottons, old pillow cases and quilt covers, and old shirts.

Tip! These masks are an excellent way to use up pieces of fabric scraps you have lying around or upcycle those old pillow cases you were planning to toss out anyway 😉.

Tip! For anyone who doesn’t feel comfortable with having to wear a mask (it can be awkward or even distressing, especially for small children), allowing them to choose their fabric gives them a chance to show off their personality and make it a little more “fun”. (For example, I see a Minions mask coming up in our future…)

Tip! I have seen people also using thin strips of stretch jersey in place of elastic. Elastic can be hard to come by these days!

Tip! Many people find wearing a face mask with wire across the bridge of the nose helps the mask fit more snugly.

***Updated*** If you do choose to use a strip of wire or pipe cleaner in your mask: before inserting into the mask be sure to bend each end of the wire over and and press firmly closed using a pair of pliers. This will prevent any unexpected pointy wire surprises poking out the side of your mask.

Choose From 3 Face Mask Sizes

Choose the size mask you wish to sew. There are 3 options and each size (obviously) requires a different amount of materials. A 1cm seam allowance in included.

LARGE

• Outer Fabric: 26cm x 19cm
• Inner Fabric: 21cm x 19cm
• Elastic: 2 x 24cm

MEDIUM

• Outer Fabric: 23cm x 17cm
• Inner Fabric: 18cm x 17cm
• Elastic: 2 x 22cm

SMALL

• Outer Fabric: 21cm x 16cm
• Inner Fabric: 16 x 16cm
• Elastic: 2 x 19cm

Tip! I have now MANY face masks using this pattern. I can share what I have learned about sizing. A Large is best for adult males. Adult females have found that a Medium mask fits best. For the children aged around 10 to 11 years I have sewn for, a Medium mask was the best option. For the children aged around 6 to 8 years old, a Small fit perfectly.

Sewing instructions step by step

Note: The method to sew the face masks is identical, regardless of whether you choose to sew a small, medium or large.

Step 1:

Cut the outer layer fabric, inner layer fabric, elastic and wire (if using) according to the size face mask you want to make.

You should have 2 rectangles of fabric (inner and outer layers), 2 lengths of elastic, and 1 piece of wire (optional).

Step 2:

Place the outer and inner layers of fabric right sides together. Pin along one long edge and then sew the 2 layers together using a 1cm seam allowance.

Optional! If you wish to use wire across the bridge of the nose, now is the time to sew it in place! Lay open the 2 fabric layers, wrong sides facing upwards. Tuck the length of wire inside the 1cm seam allowance of the inner fabric layer. Ensure the wire is centred along this sewn edge, pin the seam allowance closed and stitch alongside the wire to close. The wire will now be enclosed within the seam allowance of the inner fabric layer. This will be the top edge of your mask.

Once again, place the outer and inner layers right sides together.  Pin along the opposite, unsewn long edge and stitch together.

You will now have your 2 pieces of fabric right sides facing, sewn together along both long edges.

Step 3:

Turn the fabrics out, so that the right sides are both facing out. Iron the seams flat.

Step 4:

Fold the layers in half lengthways so that the right side of the outer fabric layer is together. Press the fold flat with an iron.

Step 5:

Measure 4cm from each end of this fold and mark with a pin.

Sew 1cm from the edge parallel to the fold, only between the raw edge and the 4cm marker. Do not sew along the entire fold!

You will now have 2 short lengths of stitching, one along each end of the fold.

Step 6:

Open the fold and iron along the long edge to flatten. The stitches you sewed in Step 5 have now created a pleat.

With the right side of the outer fabric layer facing upwards, fold one long edge of the mask over to meet the ironed pleat. Press this fold flat with the iron.

Repeat with the opposite long edge.

You will now have the inner fabric layer showing and the 2 long edges meeting in the middle and pressed flat.

Step 7:

Use the same technique as in Step 5. Measure 4cm from the raw edge along the fold, mark, and sew between raw edge and 4cm marker using a 1cm seam allowance.

This step however, needs to repeated on both ends of both folds! ie you will be sewing 4 short lines of stitching.

Step 8:

Once again, open up the past and use an iron to press the pleats flat. You will now have a mask with a top edge (which may contain a wire to fit the mask better to your nose, if you chose to do so), 3 long, even pleats and an enclosed bottom edge.

Tip! Make sure that all 3 pleats are facing the same way when ironed! The face mask will look more professional and sit better!

Now it’s time to work on the raw side edges!

Step 9:

Lay mask with inner layer facing upwards. Fold one raw edge over inwards 1cm and iron flat, so that the inner layers are now facing together.

Fold that fold once again inwards 1cm and press flat.

Repeat this technique at the other raw edge: fold, iron, fold again, iron again.

The raw edges are now hidden within those folded ends.

Step 10:

Time to sew the bands of elastic which will loop from the mask around each ear.

At each of the newly-ironed folded ends, carefully open one of the ironed folds. This is where the ends of the elastic will be attached.

Tip! Because attaching the elastic straps involved pinning and sewing together multiple layers of fabric and elastic, I have found it way easier to tack the elastic ends in place before attempting the final stitching. Otherwise it may slip out before being sewn!

After opening up one layer of the fold (you will now see that raw edge again 😉), align the end of one elastic strap with the raw edge, approximately 1cm from the top edge of the mask. Pin in place. Loop the elastic strap around and pin it in place approximately 1cm from the bottom edge of the mask. Pay attention that you don’t twist the strap before pinning it!

Repeat at the other end of the mask using the 2^nd elastic strap.

Tack the straps in place, then refold the second fold back over to hide the raw edges.

Step 11:

Bend the elastic straps up and over the fold and pin in place. You will now have an elastic loop on each end of the mask.

Sew the length of each end of the mask closed, so that the doubled over fold and elastic straps are firmly held in place.

Hurrah! Your homemade, fantastic fabric face mask is complete!

And that’s it!

Tip! I have one final piece of advice for you when you sew a face mask: If you know that you want to make more than one, work through each step for all of the masks at the same time. While the masks are not difficult to make, there is quite a bit of running back and forth between the sewing machine and the ironing board. If you can complete each step for multiple masks, it will save you lots of time! 😊.

Stay safe. Stay healthy. And where possible, #stayathome. If you do need to go out, keep your mask handy 😉.

I’d love to hear how you liked this face mask tutorial and see photos of your finished project! Be sure to tag me @everythingsfamtastic when you show off your hard work!