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I was really annoyed by the masks I've been wearing. When I talked or took a deep breath the mask would suck in and make it harder to do either. During photo sessions that wasn't acceptable so I went down a YouTube rabbit hole watching mask makers in action, took what I liked from here and there, and made dozens of prototypes until I finally settled on this system and design. From cutting the fabric to inserting the elastic, it takes about 15 minutes to make one. I'm not an expert at sewing so my directions may be subpar but the photos should make it all clear. Help yourself and wear your new mask in good health!

 

Make A Pattern

Cut out a paper 11x8 for an adult size mask. For a tween size mask, dimensions should be 10x7 and child size 9x6.

Fold the paper into quarters. On the corner that does not have any folds, measure 2 inches both along the top and side. Trim off the corner at those marks.

After you've cut the corners off at the 2 inch marks and unfolded the paper, it will look like this.

Prepare The Nose Wire

Cut a piece of pipe cleaner to approximately 6 inches Fold the ends over.

Prepare the Ear Elastic

Cut two pieces of thin elastic to 14 inches.

Prepare the Fabric

Lay your fabrics down with right sides together. Cut them following the pattern you made.

Sew The Mask

Pin the fabrics together. Sew a 3/8 inch seam around all the edges. Leave a space along the top to turn the piece right side out and insert the nose wire.

Trim the fabric away from all the corners you've sewn.

Turn it right side out.

Along the bottom, sew a seam 1/8 of an inch from the edge. Along the top, sew a seam one inch down from the edge. Insert the wire into the little pocket you've made.

Tuck in the extra fabric in the turn hole and sew an 1/8 seam across the top, enclosing the wire.

Fold the top and bottom into the center. The top to bottom measurement should be 3 inches.

Sew an 1/8 inch seam across the top and bottom.

Open the mask with wrong side up.

Fold the mask in half; lining up the ends.

THE TRICKY PART

Take the outside corner and fold it in.

You need to fold it in and back on itself.

Pin in place and do the same to the other side.

Do the same fold to all four sides.

Fold over the edge of each side about 1 inch. Make sure the wire hasn't moved, recenter it if it has. Pin in place and do the same to the other end of the mask.

Sew an 1/8 inch seam along the inner edge of the fold you made.

Repeat on the other side of the mask.

An almost finished mask from the right side up.

To pull the elastic through the sides of the mask, I found a crochet hook worked the best.

Tie knots in the ends of the elastic to make loops to go around the ears. (Hide the knots by pulling them into the channel of the mask.) If there are gaps at the edges of the mask when you have it on you need to tighten the elastic.

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