How to Sew a Face Mask

In recent times, face masks have become an essential accessory, providing protection and peace of mind in the face of public health challenges. Learning how to sew a face mask is a valuable skill that allows individuals to contribute to their own safety and the well-being of others. In this guide, we’ll explore step-by-step instructions for sewing a face mask, offering an accessible and customizable solution for creating comfortable and effective protective gear. Whether you’re a seasoned seamstress or a beginner, this tutorial will equip you with the knowledge to craft your own face masks, promoting safety and resilience in uncertain times.

How to Sew a Face Mask in 8 Steps

Follow these simple steps to sew a face mask:

What You’ll Need

– Scissors

– Sewing pins

– Sewing machine

– Iron

– 1/4 yard of Cotton fabric

– 1 1/2 feet of 1/4-inch-wide elastic

Step1-  Fabric Cutting

You can customize this mask in various sizes. Here are the fabric pieces you’ll need to cut for each size:

– Adult (fits most): 9 inches by 6 inches (cut 2)

– Child: 7 inches by 5 inches (cut 2)

– Extra large: 9 inches by 7 inches (cut 2)

Step2- Elastic Cutting

To begin, cut two pieces of elastic, each measuring 7 inches in length. It’s important to note that regardless of the size of the mask you’re making, the elastic length remains the same. These elastic pieces will be used to secure the mask comfortably around your ears.

Step3- Pin the Elastic Onto the Fabric

Pin the elastic onto the fabric by laying one piece of fabric right side up on a table. Take one elastic piece and pin it to the short ends of the fabric, positioning it about 1/2 inch from the top and bottom edges. Repeat this process on the other side of the fabric piece with the second elastic. This ensures that the elastics will be securely attached to the fabric and properly positioned to fit comfortably around the ears when wearing the mask.

Step4- Get Ready to Sew

Position the second fabric piece, right side down, on top of the fabric piece with the pinned elastic. Ensure that the right sides of both fabric pieces are facing each other. Pin the layers together along the edges to secure them in place. This step creates a sandwich with the elastic securely positioned between the two fabric layers. The pins hold the layers together for sewing, ensuring that the elastic remains properly aligned during the stitching process for a secure and comfortable fit.

Step5- Sew the Mask

Using a 1/4-inch seam allowance, stitch around the rectangle, ensuring to only sew the edges of the elastic into the edges of the rectangles, creating a loop with the elastic. Leave a 2-inch gap along one of the long sides for turning the mask right side out. It’s important not to sew the elastic into the whole seam allowance on the sides, as this allows for flexibility and adjustability of the mask. This gap facilitates turning the mask inside out and ensures a clean and smooth finish once the sewing is complete.

Remember: Sew over the area where the elastic is sandwiched between the two fabric pieces several times. This reinforces the attachment of the elastic, ensuring it is securely sewn and won’t come loose from the mask. By stitching over this section multiple times, you add extra strength to the elastic attachment, enhancing the durability and longevity of the mask.

Step6-  Turn the Fabric

To turn the fabric, insert your hand inside the fabric rectangle and carefully flip it right side out. This action will result in a fabric rectangle with two elastic loops protruding from the sides. Next, tuck in the seam allowance from the gap to ensure the rectangle is even. Use an iron to press the fabric rectangle, smoothing out any wrinkles and creating a neat finish. This step ensures the mask looks tidy and presentable, ready for the final touches before use.

Step7- Optional: Add Pleats

While adding pleats to a face mask isn’t mandatory, it enhances the fit by conforming to facial contours. Follow these steps to add pleats:

1. About an inch below the mask’s top, gather some fabric and fold it accordion-style to form a pleat. Pin it in place.

2. Repeat the process to create two more pleats, evenly spaced apart, and secure them with pins.

3. Use a sewing machine or needle and thread to stitch along the sides of the mask, securing the pleats in position.

This technique ensures the mask fits snugly and comfortably, optimizing its effectiveness.

Step8- Finish the Mask

Topstitching involves sewing a visible line of stitching on the top layer of fabric, typically close to the edge. To complete the face mask, topstitch all around its perimeter, ensuring to sew over the gap left for turning, effectively closing it. This stitching reinforces the edges, providing durability and a finished look to the mask. 

Once stitched, the mask is ready for use. Secure it by looping the elastic around your ears and positioning the mask to cover your nose and mouth, providing protection.

  • Fabric Alternatives

For this project, cotton fabric is ideal due to its breathability and comfort. If you’re unable to find cotton fabric, consider repurposing an old shirt or using an extra tea towel. These alternatives can provide similar properties to cotton fabric and are readily available in most households, making them convenient options for crafting a homemade face mask.

  • Elastic Alternatives

If elastic is unavailable, you have a few alternatives to consider but remember they need to be stretchy as they’ll fit over the ears. Rubber bands are one option, or you can use loops cut from tights, leggings, or even socks. These items provide the necessary stretchiness and can be repurposed for use as ear loops in your homemade face mask.

  • Caring and Maintenance

To maintain cleanliness and hygiene, it’s advisable to wash your mask after each use. Simply include it in your regular laundry load and wash it as you would your other clothes. This routine washing helps ensure that your mask remains clean and effective for continued use, promoting safety and well-being.