How to sew a Fabric Face Mask
As mask shortages continue in American hospitals, there has never been a better time to put your sewing skills into action to help others. The CDC has now recommended everyone wear a mask in public to help slow the spread of Covid-19, so not only do we need to be sewing for medical professionals, but for ourselves, family, and friends as well. Yep, time to dig through that fabric stash and get sewing!
I’m using this pattern from Cattywampus Crafts by Anna Nozaki. There are many patterns out there, but I’m loving this one because it’s specifically designed for medical professionals to wear over their N95 masks. They can easily switch out fabric masks and throw them into the laundry, while extending the life of their N95 mask. This is the exact style hospitals are asking for. I found the instructions easy to follow along with, and if you have simple sewing skills and a home sewing machine, you truly can do this.
If you’re just learning how to sew, now is a great time to practice and donate your work to a meaningful cause, all while improving your skills!
Materials
Tightly woven 100% cotton or linen fabric. I used IL020 NATURAL 100% Linen
Thread
Sewing Machine
Scissors or Rotary blade with mat
Iron
Chalk or pins to mark
Ruler
Tips + Tricks
Printing the pattern: As with all digital patterns, make sure to unclick “fit to page” box when printing. This seems silly to even mention, but “fitting to page” will distort the pattern dimensions. After printing, measure your pattern piece to ensure it matches the dimensions listed before cutting into your fabric.
Cutting the 1 ½” strips: I used my 2” wide clear ruler, rotary cutter, and mat to measure and cut these super fast. Line up your ruler to the edge of the fabric and cut at 1 ½” with the rotary blade. I cut leather strips this way, too! (photo of ruler and fabric strips)
Sewing the binding: Take your time ironing here, it makes the sewing a lot easier and creates a high quality product that will hold up through lots of washes.
Your finished mask should look something like this:
I’m so happy with how this turned out. The darts allow for a perfect fit around the nose and jawline. The ties make the mask comfortable and very practical since it can adjust to fit any adult, and you can easily size it down to fit kids (print the pattern at 75%).
I hope this information encourages you to sew masks for yourself, family members, and people working essential jobs. Reach out to your local hospital to see how you can donate masks to healthcare workers. Our community of seamstresses has a unique opportunity to use the skills we have to bring safety and hope to people in a time of crisis. Will you join me?
I also hope this work brings you a sense of purpose. I hope it makes you feel a deeper connection to the people around you. I hope that keeping your hands busy and focused on a project will bring you peace, comfort, and joy in this weird season. I know it has for me.
Stay well and happy sewing,
Morgann
FS NATURAL Lightweight 100% Linen
About Author
Morgann McCoy
Morgann is the owner, designer, and seamstress behind A Well Worn Story, a sewing studio in southern Wisconsin creating handcrafted leather and canvas bags inspired by adventure.Leave a comment
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30 Comments
Grace Debruyne
Thank you for sharing this mask pattern. It is the most comfortable one I have found. I have been using them as non-medical masks. I like that all you need is the fabric and not materials that are hard to access at this time.
Mattie Groshong
I like the pattern, but I find the tutorial to be very sparse with actual instructions. Did I miss the length to cut for strips? Strips for ties and the side binding? In my opinion I don’t believe a beginning sewing could accomplish “ your mask should look like this,” without a bit more written step by step instructions? Am I missing locating something else?
Morgann Mccoy
Hey Mattie! This article is not the tutorial, but simply my tips and tricks that I found helpful while sewing this mask. The pattern and tutorial are linked in the article, but I’ll the link here as well. There is a free PDF you can download for the pattern and a step-by-step tutorial with pictures. Happy sewing!
https://www.cattywampuscrafts.com/inspiration/home-sewn-surgical-masks
Josette Luvmour
I did not find the video tutorial. Can you please forward the link?
Thank you,
Morgann Mccoy
Hey Josette! There is not a video tutorial, but a free pattern and sewing instruction PDF that you can download by following this link: https://www.cattywampuscrafts.com/inspiration/home-sewn-surgical-masks Scroll halfway down the page and you will see two boxes “FABRIC MASK PATTERN” and “SEWING INSTRUCTIONS”. Click those boxes to get the free PDFs. Happy sewing!
Sherrie Gee
I have had no luck, despite several attempts, at printing the pattern @ 75% for a child sized mask. Any advice?
Sherrie
Jane Bachmann
for some reason I am not finding the pattern in the download. Need help, please.
this looks like a comfortable well fitting mask that I’m anxious to make. thank you.
Morgann McCoy
Hey Jane! If you click on the link above in the article, it will take you to the page with a free PDF. Simply scroll down about halfway and there is a box that says “FABRIC MASK PATTERN” and “SEWING INSTRUCTIONS”. If you click on those boxes, you’ll be able to download a free PDF. Hope this helps and happy sewing!
Cathy Mueller
Good morning everyone! I am joining the sewing party a little late. I have a suggestion….I have COPD Stage 3. For those of us with lung issues who should be wearing some form of protection, be aware we most likely will have breathing issues with anything that is too tightly woven or is a molded fiber such as an n95. Even if there is a one-way valve, the breathing resistance remains an issue. I will be making a few using some linen, some batiks and different weights of interfacing. My comments are fairly broad brush regarding breathing resistance and COPDers….we share a multitude of issues but some are more restricting for individuals where as some issues are not applicable. Just a thought…..Best of success to all.
Morgann McCoy
Cathy, thank you so much for sharing this! One of my aunts has COPD and I know the struggles that come along with it. You make an excellent point about the breathing resistance and its relationship to the fabric weave. There are so many different people and experiences to consider. I really appreciate your comment. Wishing you good health!
Cathy Cole
You were very clear, Lynda. Thank you for another option, and wonderful instructions.
Cathy Cole
I meant, you were very clear Morgann McCoy.
Morgann McCoy
Thank you so much for the kind words, Cathy! Happy sewing 🙂
Morgann McCoy
Hey guys! You’re all absolutely right about a tightly woven 100% cotton fabric being the best option – I mention that first in the article! This one is specifically designed to fit over an existing N95 mask for an extra protective layer, not meant to be worn on its own, so that they can easily take it off and wash in between every patient. Cotton is sold out at a lot of online stores, so this is another option for extending the life of the N95 masks. Doing what we can with what we have. You can read more about that by clicking the pattern link. I’m sorry if that was not clear in the article!
If you are wearing one mask, a tightly woven 100% cotton fabric with interfacing and a piece of wire around your nose is BEST. I wrote about how to make one of those on my own blog here: https://www.wellwornstory.com/blog-2/makeyourownmask
That said, keep the advice coming. We are are all in this together and things are changing quickly, so any research you have to add here is helpful. Thank you all so much for caring and sewing for others! So cool to see!
Amelia Vaughn
Thank you so much for submitting this. I am an acute care Physical Therapist, and yes I’ve been working with COVID19 patients. You are exactly right, we have been having to use the N95 with an additional surgical mask over it to try to protect our N95. This is a great way to preserve the now precious N95 masks.
However, the general public is not wearing the N95, and I think this is a great gift to us as we seek to find ways to protect ourselves and our families when we have to go out into the community.
With that, the articles I have read state using at least a 200 thread count material is best with a pattern that allows 2-3 layers of material, which yours does (not for N95 protection, but just to wear generally.) I am scouring the website to see which of the linen is the higher thread count. I”m sure the higher count linen will be a great fabric for those who are making masks for their family to wear outside the home in this difficult time. Also, you can center and whip stitch or zig-zag a 2-3 inch piece of chenille wire to one side of the mask to make a mold-able nose piece.
I hope and pray that this is over soon!
God bless you all.
Morgann Mccoy
Thank you so much for your kind words and for the work you are doing with COVID-19 patients! I appreciate you sharing your knowledge with us from a first-hand experience. Grateful for you. and praying for your safety. Thanks again, Amelia!
Lynda Gillow
Since this is intended to be used WITH an N95 mask, you don’t want it too tightly woven to impede breathing. I agree that I would want something different if wearing it alone.
Morgann McCoy
YES the intention of this specific design it to wear over a N95 to extend its life. If you’re intending to wear one mask for personal use, this pattern can definitely be used in a 100% cotton with interfacing. The fit is amazing, so I still recommend it for that! Thanks for your comment Lynda.
Jan Gauvain
I have been making masks for a month with a lot of research. Linen is NOT the right material. Think tightly woven fabrics, one of the top materials are batiks. I line mine with herpa filters cut from cloth vacuum bags, which are probably not available anymore, at least on Amazon. I also sew a 6 inch wire in across the top to fit very close to the face to offer the most protection for our health care people, front line workers (charities) who feed and nourish those who are struggling just to eat, EMS, police, school workers helping children in many ways. I hope many of you will consider using your skills in service to others no matter how you decide to make yours.
Lynda Gillow
Please check your filters and make sure they are safe to breathe through. Some filters used materials that are not safe in the lungs.
Morgann McCoy
This specific design is for wearing over a N95 mask to help extend it’s life. If you’re making/wearing a mask to be worn on its own for personal use, a tightly woven 100% cotton is best and I recommend using a non-woven fusible interfacing in between the layers of cotton. I was able to find some on Etsy. You can read my other article about personal face masks on my own blog here: https://www.wellwornstory.com/blog-2/makeyourownmask
colleen Rourke
We are not to use those HEPA type filters because they are fine glass which can be inhaleable. Even worse when they are cut through there are little pieces that are then inhaled thus damaging the lungs.
Jennie Bennett
Yes, linen will not do. I don’t have cotton fabric to hand, but I did make masks from tight weave silk that I use. With the pleating, that’s 12 layers of silk. If it is pre-washed, and does not have a strong color (which bleeds) silk is a strong contender, as it is tight weave and breathable. Also it dries very quickly after washing.
Morgann McCoy
Awesome to hear that you’re making masks, Jennie! This specific design is for wearing over a N95 mask to help extend its life, not meant to be worn on its own, so the linen works well in this situation. I love that you are getting creative and using what you have. Any covering is better than nothing for personal use! Before I made my own mask, I was using a linen bandana because it was better than nothing before I could get the BEST materials. Thanks for sharing and happy sewing!
Shari Thorley
I adore linen also, but it is to open a weave to make good masks. I have been making masks and they request tight woven cottons. That being said I will try this pattern as it seems to cover a bit more.
Morgann McCoy
Hey Shari! So awesome to hear that you are joining in on making masks! This specific design is for wearing with a N95 to help extend its life, not meant to be worn on its own. A tightly woven 100% cotton with a non-woven fusible interfacing is definitely best if you’re wearing one mask for personal use. I wrote about how I’m making those on my own blog here: https://www.wellwornstory.com/blog-2/makeyourownmask but I hope you try out this pattern because the fit is wonderful!
Shelly Skilton
As nice as this tutorial is, linen is WAY DOWN on the list (there was a study) of appropriate fabrics to use for this type of project. The weave of linen is just too loose & large to be an effective barrier.
Marcelle George
Shelly,
Thank you for posting that!!! I totally agree! I have been making tons of masks for front line workers and I would personally NOT use LINEN…..I LOVE MY LINEN……and I am no expert, but……please people do your research!!!! Then make an informative decision!!!
Morgann McCoy
Hey Shelly and Marcelle! I’m so happy to hear that you guys are making masks and putting lots of love and care into them. So cool to hear! This specific design is for wearing over a N95 mask to help extend its life. It can easily be taken on and off to be washed, but is still breathable to wear with the N95 mask. I’m also not a health professional, but from my research, I have found that a tightly woven 100% cotton fabric with a non-woven fusible interfacing is best if wearing on its own and for personal use. I wrote more about that on my own blog here: https://www.wellwornstory.com/blog-2/makeyourownmask but this pattern would be great in a 100% cotton. The fit is wonderful!
Amelia Vaughn
The author specifically states this is not for use alone, but for an N95 cover. As a healthcare professional, I can tell you she is exactly right, we have been using a surgical mask to wear over our N95 to keep it clean….we are expected to have one N95 per week….unless it gets dirty. This is due to the very significant shortage of the necessary N95s. I am very thankful that FS is making the effort to make this pattern available. You can easily substitute the finer weaved linen in the place of the natural heavy linen, which I plan to do for wearing out in the community. Also, I just I love the smell of linen. I hope everyone is staying safe and healthy.