Contemplating the ever-rising pollution level on our Earth, the respiratory face mask will soon become an essential item in our life. Every year around May till August, we will be attacked by terrible haze, as our neighboring country started to mass-burn their plantation wastes during this dry weather period to clear out their land while producing fertilizers for the next cycle (hmmm, not a right way to recycle, huh~).
The hazardous smokes and burning particles were being transported by the wind which is blowing towards us, settled in and won’t go anywhere else unless the rain washes them down. At times, the API (Air Pollution Index) can go up to 400 (hazardous) in a certain area. The haze is dusty, smokey and obscuring the clarity of the sky, the most important thing is that it caused eye and respiratory irritation, it is life-threatening especially to the young and elderly person, and those with weak heart and lungs.
Besides limiting the outdoor activities and switch on air purifier at home, my BFF and I urgently needed the face mask for our kids to wear. Like most kids nowadays, they have weak lungs and vulnerable respiratory system, the haze will impact a lot on their health condition. What makes us furious and anxious was that the kid’s size face mask was out of stock in the market. So, I sewed up a storm on this double-layered face mask recently and gave some away to whom who needed them.
In order to share out more so that you can sew your own washable and reusable face mask, I made the pattern into 3 sizes, small kids (around the age of 3-6, young kids (7-12) and Teenage & Adult. Not recommended for baby. It is not medical rated but good enough to filter out those haze particles and bad smell.
Before you start sewing, please pre-wash all fabrics before sewing, and wash it again prior wearing it. In this tutorial, I used quilting weight cotton on both layers, which is good enough for basic filtration. Besides, I sewed some in cotton flannel as the lining too, the filtration is even better but not recommended for small kids as it might be a little difficult for them to breath through properly.
Apart from wearing it on a hazy day, the face mask would be good for the motorcyclists, bicyclists and whoever needs to travel on a heavy traffic road. Exhaust gas from motor vehicles is even perilous and unhealthy! Also, you can use it on your sick days, to prevent spreading the viruses via your respiratory discharge.
Just a suggestion, you can also DIY the face mask for something fun, for example, adding some drawings on a plain white face mask like a “Red Hot Lips”, “No-Teeth”, “Skeleton Teeth” (a perfect match with the skeleton costume during Halloween), or any funny smiles!!! Just to have fun 🙂
See us posing for the face masks… For Better Life, cheers!!! ***camera rolls***
Face Mask Sewing Pattern
Free face mask sewing pattern & tutorial on how to sew double-layered mask. In 3 sizes, small kids, young kids and adult, with changeable elastic bands.
Materials
- Material:
- 1. Main Fabric (cotton), 12" x 6", prewash
- 2. Lining Fabric (cotton or flannel), 10" x 6", prewash
- 3. Round Cord Elastic Band 1/16" (you can buy from hair accessories section, or here), 16"
- Face Mask Sewing Pattern
Tools
- 1. Sewing essential
- 2. Sewing Machine or hand sew
- 3. Iron
- 4. Seamstress tracing wheel and paper
Instructions
- Download and print out the Face Mask Sewing Pattern.
- Pin to fabric, trace and cut out the fabric pieces.
- Sew, clip curve along on the seam allowance, turn face mask right-side out. Topstitch.
- Sew ears to the face mask. Insert elastic cord to the ear-pocket.
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More Details on how to sew the Face Mask
Download and print out the Face Mask Sewing Pattern. Don’t scale the printing, it is in letter size paper (8.5″ x 11″) so you should have no problem printing it in full scale. There is a 2″ scale marking for you to check if you are printing it in the right size.
Cut out the pattern of your size.
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[Important: Don’t print the pattern from the browser, the size is not correct. Please open the pdf pattern in Adobe Reader or Adobe Pro and print from there]
Fold the main fabric into halve with the wrong side facing each other, pin the paper pattern onto the double-layered fabric. Cut the fabric with 1/4″ allowance, except the ear side. Cut the fabric at the ear side with 1″ seam allowance.
Insert the tracing paper between the layer, trace sewing lines with tracing wheel.
Remove pins and paper pattern, get set to sew.
Repeat the same as the main fabric, except the ear side seam allowance. Cut the fabric at the ear side with zero seam allowance.
Turn the face mask main piece with right side facing each other, sew the centerline of the face mask.
Clip curve along with the seam allowance, be careful and don’t accidentally clip on the stitches.
Press seam allowance to one side, topstitch near to the seam line on the side where the seam allowance is.
Repeat the sewing on the lining part.
Flip the lining and place onto the main face mask, align the center seam line, pin and sew the top and bottom lines.
Turn the face mask right side out. Press seam neatly and topstitch near the edge.
This is how it looks like from the inside at this stage. The main fabric of the side ear area is longer than the lining piece. This is going to be the pocket of the elastic band.
Fold in 1/4″ at the raw edge of the side ear, fold again so that the first fold edge is 1/4″ from the lining raw edge.
Sew a straight line down, don’t forget to perform a few back stitches to lock the thread end.
Measure and cut the length of the elastic band needed (usually around 6″-8″ depending on the size of the face).
Insert the elastic band through the pocket and tie a dead knot to the ends.
Repeat the same to the other side. Pull the elastic band until the knots are hidden in the pocket.
Wear and breath!
Thank you for this pattern. I live in Italy south Italy to be precise.. and the smog here is going to be high level as big cities as Milan or Rome.
I would like to make also a mask with a material as much effective as possible.. I read an article from a medical suggestions about these masks and he says that the fine powders are very hard to filter. you can translate automatically this pag just to have an idea:
https://www.wired.it/attualita/ambiente/2017/11/20/davvero-possiamo-respirare-meglio/?gclid=EAIaIQobChMI8PzH6fKf5QIVQ5nVCh1a3gNiEAMYASAAEgIb-PD_BwE&refresh_ce=
Anyway, the fabric like for example licra? lycra? since are so elastic and looks very good to filter, do you think is ok? thanks for the info!
Postaram się uszyć dla dzieci chorych na raka.Dziękuje za wzór i opis jak uszyć.
Translation (by Google):
I will try to sew for children with cancer. Thank you for the pattern and description of how to sew.
Haha! I apologize, I just realized you already have the cutting up there, thank you!
Hey, uh, so I’m new at sewing and I wasn’t sure how you cut your fabric, because it skips right to the pinning and sewing and all that without showing how to cut it to that shape, so can you please add that on, or send me a link, or something? Thanks a lot, I love your mask idea!
Glad that you have found the info eventually.
I work at a children’s hospital and we have volunteers making these masks for patients of all ages. The feedback we have received so far is the elastic cord bothers their ears after wearing the mask for more then 30 minutes. What type of elastic cord do you recommend? These masks make going through treatment better! They are definitely a conversation starter. Thank you!
I used a thicker elastic cord with is mean for hair band.
I would love to try this face mask especially with my wifes health at risk after cancer treatments but i cant seem to be able to download this pdf file. would there be any other way i can have this emailed to me. i would be very grateful . TIA Cindy
Please try this link.
Happy sewing.
This was easy to sew and perfect. Thank you so much.
Thank you so much for this pattern! I’ve seen them available for purchase, but I’d much rather make them for my family, myself. I love the picture of you and your beautiful family!
Thank you for the pattern. I am making these for my family and friends who effected by the 2.5 micron air pollution in Bangkok. I tweak the sewing a bit by rather than sewing the two layers shut I make the opening for the N95 filter to fit in between the layers. Thank you again. Going to be busy with these for a while as I got to make about 30-40 of them LOL
Happy sewing 🙂
Thank you so much for this mask pattern. I was looking on Amazon to buy some cute ones and they were very expensive to buy several. Now I’ll be able to make several for less that the price of one and they can be colors that we like instead of just settling on something we really don’t love.
Sheri Reese, USA
Glad to know this, Sheri, please go ahead to sew up a storm. It is a great stocking stuffer too.
Hi! Is cotton woven okay with this? What other type of cotton can I use aside from quilting weight cotton?
Hi Jocelyn, a higher thread-count woven fabric is preferred since the face mask is meant for filtering of air particle.
Thank you!
Great, just what I was looking for! Thanks very much for this pattern, I’m going to make a couple of these today, ready for s big plane trip soon.
Thanks for such a great pattern. It looks easy and should be quick too. I have a very small childcare in the states and it’s been a horrible year for flu and cold. Next year I plan on being prepared when I hear the first sniffle! Thanks!
You do beautiful work. My pattern came out 1 7/8″ but I can fiddle a little bit to make it match 2″. I am very thankful you posted this. We have building a house for 10 years because of things like me swelling every time I go out there. The dust gets to me in no time. I am hoping with organic cotton face masks with thin cotton batting inside for me and my daughter might allow us to clean the dust and make it so we can move in soon.
Thanks so much for sharing ! its really useful for dusty weather !
Thanks so much for this pattern! I have severe asthma and I used your pattern to make a double layer fleece mask for winter. My husband calls it the “nose cozy!” It allowed me to spend more time outdoors without a single cold temperature induced asthma attack. I plan to make more.
I’m about to make several cotton and silk masks for pollen season so I can garden and exercise outdoors. For me, your mask pattern has been life changing. Thank you so much for sharing it.
Best regards,
Mary
I am glad to know that the pattern helps in improving your quality of life 🙂 Happy 🙂 🙂
Thanks for the pattern! My 4 and 6 year Olds are germ monsters, we’ve had a virus bouncing between them for months now! Even if they’re not medical grade I’m hoping that these will keep some of the ick contained. I’m making a couple for myself as well because I also have a 1 year old, and I agree, I don’t want to stick anything on her face. My first 2 were a flop because I jumped into it and didn’t read the instructions, but tomorrow I’ll make more!
Happy sewing Aimee and keep the germs away 🙂
What is the main reason for lining with flannel? I’m from a warmer area, and I really just wanted to make this to filter out dust while I’m cleaning because I have terrible allergies. I was just wondering if it was mainly for warmth, better filtration, or a combination? Thanks!
The flannel acts as both warmth and better filtration. You may use cotton to compromise thickness 🙂
Hi there! Looking forward to starting on some masks as soon as I finish breakfast. I live in Oregon so right now we’re ravaged by the smoke and ash from the Columbia River Gorge fires so masks are a must as I have respiratory problems and my husband works outside. I’d like to also make them for my kids/their friends. My question is: do you still need 16″ of elastic for the smaller sizes? Or is it just for the adult size.
Hi Jaimie, You don’t need the full length of 16″ for the mask. Cut the length according to size of the wearer.
Hi – thanks so much for sharing. I have a small daycare in my home w 2 three year olds. The one just doesn’t get to cover her mouth and turn away when sneezing or coughing. I’m totally going to make these up. They don’t get sick often but this should help. Thanks so much! These would be good for warmth during the winter outside as well
So you used cotton on the outside and flannel on the inside? But your thinking cotton for the front and back for little kids? I’m almost thinking that would be better too.
What a great pattern! Thank you for sharing. I am looking to make on for a 1 year old baby. Do you have a smaller size or could you suggest an amount for me to trim to make it work?
Thanks again for any info,
I don’t recommend a 1 year-old baby to wear handmade face mask. Sorry that I can’t give you the smallest size.
Thank you so much for this great pattern and tutorial! I was looking for fabric mask patterns for a friend of ours who will undergo surgery soon and needs to keep germs away before and afterwards. The small pattern is a perfect fit for the four year old. The shape is really great. Thank you for sharing!
I’ve been wearing disposable masks to mow the yard and I found this while I was searching for a swimsuit pattern to make my own lightweight shorts to work in the yard.
Never thought about a fabric mask. I cut one out and sewed it together tested it out then cut a strip of aluminum from an adult refreshment can -glued it on the outside of top center of mask. This way I can mash fit the strip across the bridge of my nose! Have to hand wash and air dry them (6 for now) but they save me money and start some great conversations. I just started to sew at age 60 on my wives’ machine. I started out making shop rags then do rags and now these. I’m having a blast and now I wonder why women are always complaining about sewing. I read the machines manual ,viewed some yt videos and voila!
So I’m glad I found your site and will let you know how the shorts work out asap!
Thank you so much for the face mask pattern! A volcano in my country is quite active and the ashes are spreading every were. I have my surgical mask when I study medicine ( I kept it because it was a cloth one ). I’m learning to sew I don’t fear the projects ! Now I’m going to sew yours and give away the face mask for my neighbors and daughters. I do it for free and yes I will mention to them where I got the pattern .
I try for me my girls and charity.
Yes I work as a doctor less than part time because I love been a mom plus I have MS. Fell in love with sewing and crafts. They are my best therapy!
Thanks Carolina Cortes from San Jose , Costa Rica .
I’ve been looking everywhere for a pattern for face masks. I live in an area surrounded by cement plants so breathing outside is difficult so I started wearing masks. I have a few patterened ones I’ve bought, they’re nice but they’re one size fits all so they don’t exactly fit so thank you for sharing this
Awesomeness. ..thank you for sharing…my daughter is taking Chemonfor LUPUS and has to wear mask out in public to keep from getting getting ill. These will add a little fun since at 23 she is extremely self conscious.
Hello I tried to print for face mask pattern but it won’t and I did printed 7 and 5 (12 pages) colour print papers without a pattern of face mask as waste my money for colour ink as I am not pleasure with this. 🙁 PLEASE send me this pattern to my email. Thanks
Hi Barbara, I think you were printing out the tutorial page, the pattern template is available here.
Happy sewing.
I just found your pattern and I sincerely appreciate your sharing your hard work. I am always embarrassed in a paper mask but these are fun and attractive!
hope u have video of this
I have been going crazy trying to find a pattern for my daughter. She has an autoimmune disease called Behcet’s. She was recently on a new medication that causes her to be highly susceptible to colds/flus & other illnesses. So, while she’s on them we’re going to use these to keep her out of the hospital. Thank you SO much for sharing your pattern.
I am happy to know this, Sherrailynn. Hope she gets well soon 🙂
Fantastic pattern – simple to follow and make!!! Thanks very much for creating and sharing it, Joanne. I have just made one up for myself (as part of my ‘vomit kit’, lol! – my young kids recently had their very first vomiting wog and at the time, I wished I had a face mask so I didn’t have to smell and breathe in the vomit stench) and have made a couple for my kids for their dress up box. It is a great pattern (I love your inclusion of various sizes) and was so easy to make – the masks turned out very professional looking too. Thanks again!!!
This is another good use of face mask, LOL!!! Have a nice day, Anna!
Thanks for providing this pattern. I use up those paper allergy masks to fast and is becoming expensive. These look nicer too.
how long can a kid wear it because most mask are only good for 20 mins.
thanks for the idea .
Thanks so much for the pattern. I work in an old office bldg and many people come in sick when they shouldn’t. Buying pre-made washable masks are expensive and not really doable on my budget. I will be raiding my m.i.l. fabric stash this weekend!
Hi dear, love your face mask design very much and since we now are having bad weather some of my friends are really interested to buy this face mask from me. Please email me regarding your pattern if i need to pay for it.
I am fine with you to make and sell the mask with this free pattern.
thank you for the face mask pattern. this exact shaped mask was sold in malls for $6 and i managed to do it for a fraction of the price. and i have to say it turned out lovely too!
Wow, that’s great!!! Happy to know that the pattern has given you some saving.
Hello Joanne,
Is there anyway I could purchase this face mask from you?
Thank you in advance.
~Funn~
Sorry, Funn, I didn’t sew the face mask for sale. It is easy to sew and I am sure you can do it and it will save more money if you sew it yourself.
God bless you. I’ve been looking up for tutorials for how to make a face mask but I couldn’t find any. I always watch a lot korean celebrities wear masks and I want to make one. I thank God for finding you.
Thank you for this, we are having massive wildfires in British Columbia and the air in Vancouver is full of smoke and ash, and it’s making all of us sick, so I’ll be sewing this when I get home tonight!!
Sorry about the bad air quality in your area. Please sew this face mask for your friends and family members too.
Thank you so much for sharing this pattern! I’m allergic to dust (well more accurately the dust mites) and I’ve been looking for a reusable mask that I can wear when I’m cleaning. This works very well and is so easy to make.
Monique, I am happy to know that the pattern solves your allergy problem 🙂
Would like to say thank you for this pattern. When I found this I was looking for something for my grandson that was washable as well as breathable for him (his 3yrs old). Found your pattern and have since made him at least 4 in different fabrics. I even made one for his mom & dad…hahaha. I made one for myself recently due to sinus infection from air at work. They are wonderful and work great!!!! thanks again for sharing your pattern, you have blessed me in providing something useful for my grandson (he has PCD–involves lungs). Be blessed.
So glad to know this, Sherrie, my weekend is meaningful!!!
Thank you so much for this pattern. I have respiratory problems so I cant afford to catch colds or flu’s. This mask will help me so much!!! And I can make them in fabrics and colors to go with my outfits!
Perfect for my asthma, since I live in Texas and it is too hot to always wrap a scarf around my neck and mouth or difficult slouching in my light weight jacket to block the cool wind from my face. I am so excited about the convience of these for my asthma.
Thank you so much for this pattern. I am new to sewing and I am looking forward to this project.
Thank you for this!! We need this for motorcycle riding and its perfect!
Seriously, this is brilliant. I have dust, mold, and grass allergies. Plus wear a mask when cleaning cat boxes. The store masks are not up to the task, with this wonderful pattern, thank you very much, I can adjust them to suit individual purposes. I love the idea of the red lips!
I am so glad that this pattern could be a good help to ease your allergy problem.