Santa Face Mask Sewing Pattern

Instructions

1. Download the PDF file of the Santa Face Mask Template separately. Decide which size you want to sew and print the pattern out on heavy paper or card. Cut paper templates for tracing.
2. Trace the templates on the fabrics accordingly then cut them out based on the quantities stated on the templates.
3. Sew the Face Mask with quarter inch seam allowance as instructed, with matching color thread. Clip curve on the arched seam allowance or trim the seam allowance with a pair of pinking shears.
4. Press seam to a side then top-stitch near the seam line (sew on the seam allowance side)
5. Sew beard and nose on the mustache then place the mustache on the front of the Santa Face Mask. Aligned them, pin and topstitch near the edges of the mustache to attach it onto the face mask.
6. Sew nose wire sleeve to the lining, this is optional, you may skip it if you do not want a sleeve for removable nose wire.
7. Place both front and lining pieces with right side together, align on the center seam, pin and sew, clip curve on the arched seam allowance. Turn the Santa Face Mask right side out. Sew ear loop tunnel to complete the face mask.
8. Add elastic ear loops or head ties to the face mask.
9. Wash the face mask with warm water of at least 60 °C or 140 °F, dry it properly before wearing.

More Details on how to sew the Santa Face Mask

PREPARATION

Prewashed all your fabrics and make sure the red fabric is color-fast.

Download the 4 sizes Santa Face Mask templates PDF file, choose the size you want to sew and print them out on heavy paper or card. It requires 2 pcs. of paper for each size. Make sure you disable all the printing scale of the printer setting, or, print it to the "actual" size setting. Measure the 2" scale that's available on the template after you have printed it out and make sure you are getting a 2" measurement on the ruler too, that means you have printed the template in the correct size. If you didn't get the correct size, check your printer setting again, and also make sure you are not printing it from the browser (the browser setting will overwrite your printer setting).

Cut out the paper templates. Solid lines are template includes seam allowance. Dashed lines are stitching lines. Arrows are the direction of fabric grainlines.

Notes: Not all the fabrics shown in the pictures are used in sewing the Santa Face Mask. The actual beard template is bigger than the one shown in the picture.

Trace and cut out the fabric pieces.

The cherry red fabric is for the Front piece.

The white fabric is for the Beard, Mustache, and Lining pieces.

The red fabric is for the Nose.

Notes: Again, not all the fabrics shown in the pictures are used in sewing the Santa Face Mask. The actual beard template is bigger than the one shown in the picture.

SEW FRONT PIECE (SANTA DESIGN)

Front Piece

Place the front pieces right side together, sew the center seam then clip the seam allowance with pinking shear or scissors.

Press seam to the side, then, topstitch near the seam line (on the seam allowance side) from the right side.

Set aside.

Mustache Piece

Place the 2 sets of Mustache pieces right side together, sew the center seam then clip the seam allowance with pinking shear or scissors.

Press seam to the side, then, topstitch near the seam line (on the seam allowance side) from the right side.

Place both pieces right side together, align, pin and sew the bottom edges together. Clip the seam allowance with pinking shear or scissors.

Turn the mustache right side out, press seam open with the finger then align the edges well, press with an iron to give a crisp neat edge.

Set aside.

Beard Piece

Trace the Beard outline on the wrong side of a piece of white fabric. Stack it on another piece of white fabric with the right side together. Sew around. Clip the seam allowance with pinking shear or scissors.

Carefully slip a verticle opening at the center of a layer of the Beard piece. Turn Beard right side out from the opening. I like to use a pair of blunt-point tweezers to do the job, it helps to push the seam edges out too. Press.

Sew to close the opening, then topstitch near the edges.

Nose Piece

After tracing and cut out the Nose piece from the fabric, sew around the edge with running stitches.

Place the nose paper template (without seam allowance) on the wrong side of the fabric, pull the thread to draw the edge of the fabric to the center, pull tight, and knot the thread. Press.

Pinch to take out the template of the nose piece.

Assemble Santa Mustache

Refer to the template, mark the positions of the beard and nose on the mustache. Stitch the top of the beard to the mustache (within the width of the nose marking).

Place the red nose on the mustache, slip stitch it along the edge to the mustache. You may stuff the nose with some batting or poly filling to make it looks round and fuller.

The stitching may go through both layers of the mustache fabrics, or, you can do on the outer layer only.

This is how it looks like after sewing the beard and nose to the mustache.

Now, place the mustache onto the front face mask piece, align the center seams and top edges, pin.

Top stitch near the bottom edges of the mustache.

This is how it looks like from the back.

Trim The Layers (Optional)

With 2 layers of mustache fabric and 1 layer of front piece fabric, you have a total of 3 layers for the front assembly, and, it will be 4 layers after the lining is sewn on. If you want a super thick 4 layers face mask for better filtration (may be challenging in breathability though), then you may attach the lining piece to the Santa Face Mask. Otherwise, you may want to trim out the layers as shown in the following instruction.

For 3 layers of Santa Face Mask, trim out the Front piece (Cherry Red fabric) by carefully cutting 1/4" from the sewing lines.

For 2 layers of Santa Face Mask, trim out another layer of Mustache piece just like above. If you have sewn the beard piece and nose piece through both layers of Mustache fabric, carefully cut it 1/4" away from the stitches.

SEW LINING PIECE

Place the lining pieces right side together, sew the center seam then clip the seam allowance with pinking shear or scissors.

Press seam to the side, then, topstitch near the seam line (on the seam allowance side) from the right side.

ADD SLEEVE FOR NOSE WIRE (OPTIONAL)

Cut a bias strip of 2” wide and 6” long or use store-bought bias tape if you can find it from the shelf.

Fold ¼” from the 2” ends.

How to cut bias strip:

Fold the fabric diagonally, draw a line along the crease of the fold, measure 2” from the line and draw a line parallel to it. Cut the strip into 6” length.

Fold the strip into half, lengthwise.

Stitch up both ends.

Align the bias tape along the front top edge of the lining.

Topstitch at the bottom edge of the bias tape.

Do not remove the pins until you pin the main piece to this lining piece.

SEW LINING TO THE SANTA FACE MASK

With the right side together, align the center seam lines and pin the lining to the front piece. Sew the top and bottom edges with 1/4" seam allowance.

Clip the seam allowance by making small little cuts about 1/2" apart for the top edge. Clip about 4 cuts at the bottom near the center seam.

Turn the Santa Face Mask right side out. Press seam to give a crisp and neat edge.

This is the inside of the Santa Face Mask.

Topstitch near the top and bottom edges with matching color thread.

Note: I used white thread for the bobbin, and, only change the top thread to match the color of the front piece.

FASTENER CHANNEL

At the side, fold 1/4″ from the edge. Then, fold again so that the first fold is 1/4″ from the raw edge of the lining.

Sew a straight line down, don’t forget to perform a few back stitches to lock the thread end. Add your label if you have one.

Thread your elastic earloop or head ties through the channel. Knot the ends of the elastic cord and pull it into the channel to hide.