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Santa Face Mask Sewing Pattern

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Let’s spread our arms and welcome December with a warm hug together! This year, we’ve all adjusted our lifestyle to suit the pandemic, adapted to the “new norm”, and learning new skills. While it may be tough, I’m sure they’re all valuable life lessons. For example, learning how to sew a protective face mask for family, friends, and our heroic front-liners! After receiving tons of positive feedback about my 4 sizes face mask pattern, I am back with a Santa Face Mask Pattern for you to sew for the festive season 🎅

santa face mask

Like my original face mask sewing pattern, the multiple cotton fabric layers of this Santa Face Mask is bound to keep you protected from viruses. If you’re not wearing a medical mask, health officials from many countries are strongly encouraging people to use a three-layered fabric face mask, and these Christmas-themed Covid face masks consist of two to four layers, depending on how you sew it. 

Santa Face Mask

scroll ⬇️ to get the free sewing pattern & tutorial

santa face mask

Christmas is a magical time for all, but to Santa Claus and his lovely helpers, it is a lifetime career. It is months and months of work finally coming to light. It gets especially busy for everyone in the North Pole during December, and even though Santa is the big boss, things don’t come easy for him. He first has to compile lists of children from around the world, categorize them according to their behavior, then finally delivering presents to them throughout the world before 25th December. I wonder if he needs an extra helping hand by the pretty young lady in a Santa face mask. She’s all dressed up and ready to go! *hint hint*

sew Santa covid face mask

Yup, that’s my daughter right there, standing in front of our lovely Christmas tree, getting into the Christmas mood! She’s got her Santa hat on, a cheeky sock monkey in hand, and of course, her new Christmas face mask. This face mask is developed from my popular 3D “bra” type cupped structure face mask sewing pattern. It was originally designed to fight the nasty haze attack in our country many years ago, and never would I have thought it’d be used under such circumstances this year.

Santa face mask sewing pattern

Earlier this year, I took some time to further refine and redesign my haze and flu mask to meet the requirements a protective mask should have to fight against Covid-19. I am proud that my face mask sewing pattern has been recognized by hospitals in many countries! When we experienced shortages of protective gear, hospitals even asked their volunteers to use this face mask pattern to sew them some Covid face masks. 

santa face mask

Not only are adults affected by the changes caused by the pandemic, but children are also affected, maybe more than we think. They have been asked to minimize outdoor time, to learn how to attend virtual classes during the lockdown, to have more self-discipline in managing their homework, and much more. So one thing we can do to surprise them is by customizing them something adorable they can wear during Christmas!

Oh yea, if you’re living in a cold country, you can change the material of the cloth to flannel fabric and sew it as a winter face mask instead. This way, it can protect you from both the chilly weather and from the virus! 

If you’re a fan of another iconic Christmas character, feel free to check out my Reindeer and Snowman face mask patterns. Or this if you’re looking for something more classic, simple, and mature yet Christmasy.

Santa Face Mask sewing pattern for covid

Santa Face Mask Sewing Pattern

Yield: 4 sizes - from age 3 and above
Active Time: 1 hour
Total Time: 1 hour
Difficulty: Avid Beginner/Intermediate
Estimated Cost: $10 - $12

Get the free pattern below and learn how to sew this Santa Face Mask for your loved ones! Gift them a fashionable Santa face mask they can use to protect themselves with, yet remain comfortable at the same time. 

It comes in 4 sizes that are suitable for a wide range of people; from young children to adults. 

This year may be tough, but I hope that doesn’t keep you from celebrating this month with love, hope, and happiness.



  • Cotton fabric, Cherry Red, 13" x 7", prewashed and color-fast - for Front piece
  • Cotton fabric, White, 16" x 12" or 8" x 24", prewashed - for Lining, Mustache & Beard
  • Cotton fabric, Red, 2" x 2", prewashed and color-fast - for Nose


  • Elastic cord: for ear loops, 8" x 2 pcs., or, for head tie, 18" x 1 pc., (this is an approximate length, please measure with your own elastic band to judge; as everyone's head and sizes are different)
  • Or, shoelace/ribbon/cord/t-shirt yarn with at least 44" length for the loop-through head tie

Nose Wire (Optional)

  • Bias Tape, 2" wide 6" long (5" for young kids, 4" for small kids), prewashed. (Optional, as a sleeve for nose wire)
  • Wire, 6" (5" for young kids, 4" for small kids). (Optional, as nose wire), bent the ends inward so the won't poke through the fabric.

Face Mask Patterns & Template


  • Sewing essential
  • Sewing Machine or hand sew
  • Iron
  • Seamstress tracing wheel and paper, or, Quilter's tools
  • Pencil or soluble fabric marker
  • Printer and Cards or Papers (2 pcs. / size)
  • Blunt point Tweezer (optional but great for turning small parts right side out)


  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


Santa Clause face maskPrewashed 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.

santa face mask sewing patternTrace 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.


Front Piece

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

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

Set aside.

Mustache Piece

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

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

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

santa face maskTurn 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

santa face maskTrace 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

santa face mask

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

santa face maskRefer 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).

santa face mask 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.

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

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

santa face maskTop stitch near the bottom edges of the mustache.

santa face maskThis 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.

santa face maskFor 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.


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

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


santa face maskCut 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.

santa face maskFold the strip into half, lengthwise.

Stitch up both ends.

santa face maskAlign the bias tape along the front top edge of the lining.

santa face maskTopstitch at the bottom edge of the bias tape.

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


santa face maskWith 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.

santa face maskClip 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.

santa face mask sewing patternTurn the Santa Face Mask right side out. Press seam to give a crisp and neat edge.

santa face maskThis 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.


santa face mask 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.

santa face maskSew 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.

Santa Face Mask


When you press the seam to the side, ensure all pieces are pressed to the same side. This will prevent fabric bulk when you layer the pieces together.

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