Face Mask Pattern

So obviously I’ve been sewing a lot of masks. It’s been a lot of fun to use the cute quilting cottons I’ve been collecting over the years. I think it also says something about my stash that I’ve made close to 100 lined masks and I haven’t needed to order any fabric. =D

I started with using some of the free mask patterns available, and found none of them fit me very well, so I drafted my own. Disclaimer time! Everyone’s gonna get a different fit because everyone’s face is different and my pattern has been mostly tested on Asians. We tend to have less of a nose bridge so this mask was designed with that in mind.

PDF Pattern: Confused Kitty Sewing free mask pattern
(Please note that this pattern uses a ¼” seam allowance!)

  • S: fits children about 4-7
  • M: fits children about 8-12*
  • L: fits teens  to adults
  • XL: fits bigger adults

*I did not have test fit models in the upper end of this age range, so I have no idea how high it can go.
For reference, I use a L. My brother who is 6 feet tall uses the XL.

facemask facemask

I’ve been using the CraftPassion tutorial  for assembly. They have a great assembly method that includes a liner/filter pocket and a removable nose wire pocket. The only difference is that I use a ¼” seam allowance which means you don’t have to clip the seams.

I’m going to do a quick run down of assembling a mask, but I’m not going into a lot of detail because CraftPassion’s tutorial is already amazing. They even have a video tutorial, so go check out their site!

The pattern includes pieces for the mask and the liner. The liner pattern is slightly smaller so that it fits inside the mask better. I cut 2 of the mask material and 2 of the liner. I usually do the masks in batches of 8-10, as I find it more efficient to assembly line them.

facemask tutorial

With right sides together, I stitch the center front seam.

facemask tutorial

facemask tutorial

Pushing the seam allowance to the left, I topstitch to the left of the center seam to sew the seam allowance down.

facemask tutorial

I do this for both mask and liner fabric.

facemask tutorial

facemask tutorial

On the liner, I mark ½” line on both the left and right edges.

facemask tutorial

I fold on the ½” line I just drew, then fold the edge under again to hide the raw edges, and stitch it down.

facemask tutorial

facemask tutorial

To create the casing for nose wire, I cut a strip of fabric 5″ x 1 ¾”. I fold over the ends, and then fold in half lengthwise. You can also use a piece of bias tape but I never seem to have bias tape on hand. (I only put the nose wire casing in adult masks. I skip this step for the kid masks. )

facemask tutorial

I pin the  casing against top edge of liner so the raw edges line up with the edge of the mask, and then stitch down bottom edge of casing.

facemask tutorial

With right sides together, I pin the liner to the mask, matching up the center seam.

facemask tutorial

I stitch along the top and bottom edge…

facemask tutorial

Flip the mask right side out…

facemask tutorial

And press the edges.

facemask tutorial

facemask tutorial

I top stitch along the top and bottom edges, so the liner will stay in place when the mask is washed.

facemask tutorial

facemask tutorial

To create the elastic casing, I fold the right and left edges twice creating a casing that is about ⅜” wide.

facemask tutorial

facemask tutorial

I stitch down casing, and pass elastic through the casing. I like to use a safety pin to help feed elastic through.

facemask tutorial

I tie off off the elastic…

facemask tutorial

And the last step is putting in a nose wire. I have been using floral wire because I have a lot of it on hand. I’ve also seen people use pipe cleaners or twist ties. I fold it in half and twist it together, because I found one piece wasn’t strong enough.

facemask tutorial

I have been including filters with the my masks, but I leave it up to the wearer to decide if they want to put it in.

Let me know how the pattern works out for you if you decide to use it!

One comment on Face Mask Pattern

  • Mary

    Thank you for the tutorial. I’ve made a few masks like this one. I like it because it’s not as big on your face as the rectangle ones. I’ve use paracords instead of elastic so it can fit around the head instead of the ears.

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