Face Masks – part of our 2020 world and COVID-19. Physical therapy is much more difficult with a mask, so I have been looking at mask designs that are more accomodating of exercise and my glasses. I have also been looking at how these masks should fit, which seems to be quite different than how Americans wear them. Since people in Asia have been wearing masks for many years, most of the mask designs are from Asia. I watched a lot of Asian YouTube videos showing how to make face masks, primarily to see how they created the sizing. I made one of the origami-style using an “Adult Large” pattern. The face mask was too small for my grandchildren, but it did let me work with the construction and better visualize what the dimensions meant. I concluded that there are five measurements that matter.
Facial Measurements
You need to use a sewing tape measure to get the flexibility you need for an accurate dimension.
- Measure from ear to ear across the nose bridge
- Measure from ear to ear across the tip of the nose
- Measure from ear to ear under the chin. Make sure your tape measure rests at least one inch under the chin.
- Measure from the tip of the nose to the chin
- Measure from the bridge of the nose to the chin
Any mask (plus elastic or ties) should fit closely along with measurements 1 and 3. At a bare minimum, it should also measure 4 plus 1 to 1.5” so that is covers from the bridge of the nose to a comfortable distance under the chin. You can use this information to assess whether a mask you want to purchase would fit or whether a pattern is cut from a piece of material that is larger than the measurement you need.
Determining how much room you want for air and movement along measurement lines 2, 4, and 5 takes some experimentation. You probably don’t want the long beak on the medical mask from the Bubonic Plague, but something close-fitting isn’t the best either.
Origami Mask Style
Determining how much room you want for air and movement along measurement lines 2, 4, and 5 takes some experimentation. You probably don’t want the long beak on the medical mask from the Bubonic Plague, but something close-fitting isn’t the best either.
The origami-style face masks are more complicated to make, so to simplify and save costs, I use a solid colored cotton for the lining and a patterned cotton for the main fabric.
Pattern Download – Men
Pattern Download - Women
Pattern Directions
Be sure to wash your fabric in warm or hot water and dry at high heat to get the maximum shrinkage before you cut your pattern pieces.
Cut 1 Center Piece of front fabric and one of lining. You can use the pattern as is and fold the fabric along the fold line or cut out two of the center pattern pieces and tape them together so you can cut out the fabric without a fold.
Cut 2 of the Nose/Chin pieces in front fabric and cut 2 of lining.
Put the two center pattern pieces together right sides together. Iron together to make sure they match. Then iron a 1” fold on the ear sides of the lining. Based on your measurements in 1-5, choose a seam allowance for the mask. I designed this to use 3/8”, 1/2”, or 5/8” seam allowance.
Mark A and B on the fabric and the lining to make sure your turn is nice and sharp. Sew the top edge and the bottom edge of the Center Pieces together and turn right side out. Iron flat. A chopstick works well to help push those seams into place. Top stitch as close to the edge as you can along the top and bottom. The liner edge at the ear is finished. Iron in ¼” fold on the ear edges of the front fabric. Then iron in another ½” fold. Stitch down over the ¼” edge to form a channel for the elastic.
Pair up the chin/nose pieces with right sides together. Mark the points on the fabric so you can line them up correctly. With the same seam allowance used for the main pattern piece, sew the chin piece together leaving a gap open so you can turn the fabric right side out. Clip at points to make it easier to turn right side out. Using a pencil or chopstick, turn the piece right side out. Iron flat. Top stick all the way around. This closes the gap.
For the nose piece, stitch the two pieces right sides together leaving a gap – but this time make sure the gap is on the A side but not at the A point. Clip the points, and turn right side out. Iron flat. Slide a metal nose band through the gap with the front side of the metal band facing front. Leave it loose in the middle of the fabric for now. Topstitch all around. Push the metal band up to the nose bridge and top stitch around the band to hold it in the center top.
With the center piece lining facing you (and the patterned side right side up) set the nose piece lining side down on the top of the center piece with A points together. Top stitch the two pieces together and pivot at A.
Repeat with the chin piece at B. Your mask is now flat with both the chin and nose piece folded in.
Now it is time to sew your origami lines. These lines are what bring measurements 1 and 3 into comfortable but form-fitting alignment. These lines go from points A and B out to the edge of the chin or nose piece. Be sure to avoid stitching through your elastic channel.
Slide the elastic through the channels at the ears and tie together. I also attach elastic toggles or cord locks so the elastic can be easily adjusted.
