We are living in strange times. The effects of the coronavirus are far reaching, even to those who haven't gotten sick. Many common household and hospital supplies are hard to come by these days. Some are asking what they can do to help. After seeing a post on social media about the need for face masks, and that fabric ones are an acceptable substitute for the paper face masks usually used, I knew I could help in this way. Not only am I a soap maker, but I have a large stash of 100% cotton fabric from when I was an active quilter. So hi ho, hi ho, it's off to sew I go!
There are many fabric face mask variations. This is just the way I made them.
I used the "Deaconess" pattern found here, but after making a couple masks, I tweaked the pattern so that the mask would fit better over the nose, and I found a process that worked for me. A face mask with straps that can be tied will provide an even better fit, so that will be the next change I make moving forward, but in the meantime, I hope this picture tutorial will be helpful. Feel free to modify and adapt the pattern, just as I did.
I used the "Deaconess" pattern found here, but after making a couple masks, I tweaked the pattern so that the mask would fit better over the nose, and I found a process that worked for me. A face mask with straps that can be tied will provide an even better fit, so that will be the next change I make moving forward, but in the meantime, I hope this picture tutorial will be helpful. Feel free to modify and adapt the pattern, just as I did.
Cotton fabric cut 9" x 12"
Cut a 9" x 12" piece of cotton fabric. For a snug fit over the nose, I sewed a small dart on each 9" side. To do that, fold the 9" side in half right sides together so that the folded piece is 4 1/2" x 12." On the cut edge, mark 3/4" from the fold. Then mark 1 1/2" on the folded edge.
On the cut edge, mark 3/4" from the folded edge
On the folded edge, mark 1 1/2"
You can draw a line. I just eyeballed it.
Sew the nose dart on each 9" side. I sewed a few back stitches at the point to secure the dart.
Sewn nose dart
Make a dart in the middle of each 9" side
After making the two nose darts on opposite sides of the fabric, fold the fabric along the 12" side, right sides together, with the dart seams lined up and the darts facing opposite directions.
Line up the cut edges right sides together
Line up darts facing opposite directions
Sew a 1/4" seam across the cut edge with the darts. Make a slight turn where the darts intersect.
Sew across the top, turning at the slight angle where the darts meet
For the straps there are a few options. I started with 1/4" elastic until I ran out. I found that for my face, elastic cut to 7" worked well. But to fit my husband who has a larger face than I do, elastic cut to 7 1/2" was better. I read that loop straps are usually between 6 - 8 inches. This tutorial is for a fabric loop strap.
Tie straps are completely adjustable, so I will make face masks with ties going forward. Plus I'm out of elastic, as is Walmart and Jo-ann's. And I have lots of cotton fabric...
Tie straps are completely adjustable, so I will make face masks with ties going forward. Plus I'm out of elastic, as is Walmart and Jo-ann's. And I have lots of cotton fabric...
To make the fabric loop straps, cut two pieces of cotton fabric 1" x 7," or for a larger size, cut the fabric 1" x 7 1/2" as shown. Fold each strap in half with the wrong side and long sides together. Then fold the raw edge in to meet at the center fold. The raw edge will be enfolded within the strap. The strap will measure 1/4" when sewn. Yes, it's tiny and a little fiddly to do this. Using elastic is easier.
Cut and fold fabric loop straps. Using an iron is neater, but I just winged it.
Sew down the length of each strap as close to the folded edge as you can. Insert one strap into the mask with one strap edge lined up along the sewn edge of the mask and the short raw end of the strap lined up with the edge of the mask. In the photo, the short edge still needs to be lined up with the edge of the mask.
Strap inserted into the mask, along the sewn seam
Starting at the top where the strap is inserted, sew a 1/4" seam down the short side of the mask, stopping 1/4" from the bottom of the folded edge of the mask. There needs to be an opening to insert the other side of the strap later.
Leave a small opening at the folded end 
If you forget to leave an opening, it's easy enough to pick out a few stitches later. Don't ask me how I know.
Now do the same with the second strap on the other side, only this time, leave a 2" gap in the middle of the seam so that the mask can be turned right side out. Then pull the four corners of the mask through the gap so that the mask is now right side out.
Turned right side out. The opening will be sewn shut later.
At this point, using an iron to press the edges neatly together is an option. I just finger pressed the edges together in preparation for inserting the other end of the straps and sewing around three sides of the mask.
Mask turned right side out and edges pressed flat
Starting with the side of the mask that doesn't have the larger opening for turning, insert the end of the strap into the small opening at the bottom of the mask at the folded edge. Insert it far enough into the opening so that it will be sew down in the seam. Insert 3/8" to 1/2" inch.
Insert edge of strap 3/8" to 1/2" into the opening at the folded edge
Sew a 1/4" seam down the short side of the mask. Sew over the strap at the top end of the mask. I back sewed a few stitches over the straps for extra reinforcement. Next, sew a 1/4" seam across the top of the mask, turning slightly at the nose dart.
Sewing across the top of the mask
At the other side, sew down the short edge of the mask, over the inserted strap, continuing down the side, being sure the opening edges are turned inward. Be sure to insert the loose end of the strap 3/8" to 1/2" into the small opening at the folded bottom edge of the mask.
Insert the loose end of the strap before reaching the end.
Inserted end of the strap before sewing
To reinforce the side seams, sew a small 1/8" seam close to the edge of each side. This will also close that large opening on the one side where the mask was turned to the right side.
Mask with ear straps before sewing the tucks. Note the double seams.
To make the mask even more fitted, two tucks are made in the short edges. Many fabric face masks have three tucks, but with the nose dart, two tucks are enough. To make the first tuck, measure 1 1/2" from the top edge of the mask and fold under about 1/2" to make a tuck and pin in place, keeping the edges even.
Make a tuck 1 1/2" from the top edge of the mask
First tuck
For the second tuck, measure 1 1/2" from the folded bottom edge and make a tuck. The two tucks should be facing down towards the folded bottom of the mask. Pin.
Measure 1 1/2" from the bottom edge to make the second tuck.
When the tucks are pinned in place, the short sides of the mask should measure 3 1/4."
Sew a 1/4" seam down each side of the mask, removing the pins before reaching them. It is not a good thing to hit a pin. Don't ask me how I know. I back stitched at both ends of the seam to reinforce the inserted straps. Congratulations! The mask is finished.
Finshed fabric face mask
Wash and dry the mask before donating it to someone you know who needs one. Better yet, make a bunch of them and drop them off at your local hospital, hospice, or nursing home. And make one for yourself. You might need it someday.
Although we live during anxious times, we need not fear. Jesus said, "Peace I leave with you; my peace I give to you. Not as the world gives do I give to you. Let not your hearts be troubled, neither let them be afraid." John 14:27 "I have said these things to you, that in me you may have peace. In the world you will have tribulation. But take heart; I have overcome the world."
John 16:33
"For everyone who has been born of God overcomes the world. And this is the victory that has overcome the world - our faith. Who is it that overcomes the world except the one who believes that Jesus is the Son of God?" 1 John 5:4-5 "Whoever has the Son has life; whoever does not have the Son of God does not have life." 1 John 5:12
As I sew more fabric facial masks in the days to come, my prayer is that those who wear them will not just overcome the coronavirus, but overcome the world by faith in the Son who gives eternal life to those who believe.
~ Debbie
John 16:33
"For everyone who has been born of God overcomes the world. And this is the victory that has overcome the world - our faith. Who is it that overcomes the world except the one who believes that Jesus is the Son of God?" 1 John 5:4-5 "Whoever has the Son has life; whoever does not have the Son of God does not have life." 1 John 5:12
As I sew more fabric facial masks in the days to come, my prayer is that those who wear them will not just overcome the coronavirus, but overcome the world by faith in the Son who gives eternal life to those who believe.
~ Debbie
