Free Fitted Face Mask Sewing Pattern

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With demands on healthcare facilities and workers growing daily during the COVID-19 Pandemic, PPE supplies are rapidly hitting critical low levels throughout the US.

In times of emergency, when all compliant supplies have been exhausted, the CDC allows fabric masks to be used. Learn more about CDC Guidelines Here. Sewists can work together to help boost the supply during this critical time.

Disclaimer: While wearing a homemade face mask may not prevent someone from catching Covid-19, it can decrease the spread of large particles when someone who is infected sneezes or coughs.

You should wash and sterilize your face mask before and after use. Use a color safe bleach such as Clorox 2 in hot water. If you are inserting a disposable liner, remember to remove and discard the liner before laundering.

This fitted face mask pattern includes four sizes: X-Small (ages 3-6 years), Small (ages 7-12), Medium (teens and women) and Large (men). This mask is lined and has an opening to allow you to insert additional filtering material if you wish. A good filter insert would be a non-woven fabric or material. I used a coffee filter which was light weight, so it was easier to breath while adding an extra layer of filtration.

Download the Stitchwerx Designs Fitted Face Mask Pattern here.

Materials & Supplies

  • Main Fabric: Tightly woven cotton (such as quilter’s cotton)- 7 x 14”, prewashed
  • Lining Fabric: Tightly woven cotton (such as quilter’s cotton)- 7 x 14”, prewashed
  • Non-woven light weight fusible interfacing- 7 x 14” (Heat n Bond or Pellon)
  • 16” of 1/4” flat elastic
  • Sewing machine
  • Thread
  • Scissors
  • Water soluble fabric marker
  • Iron
  • Safety Pin

Before You Sew

  • Prewash and dry fabric.
  • Use Adobe Reader to print pattern page. Print at 100%, No Scaling. Measure the gauge box on the pattern page. It should measure 1 inch.
  • Seam allowance is 3/8”.

Construction

Face mask pattern pieces cut out
Cut outer fabric, interfacing and lining as indicated on pattern pieces.
Fuse interfacing to the wrong side of outer fabric pieces.
Place outer fabric pieces right sides together and stitch center line. Repeat with lining fabric pieces.

Clip curves. Press seam to one side. (Same for outer and lining sections).

Top stitch 1/8” away from each side of the center line seam. (Same for outer and lining sections).
Fold left and right edges of lining on the fold line to the wrong side, tucking the raw edges under. Press.
Stitch vertically close to the folded edge to hold in place.
Place outer fabric and lining right sides together, matching centers. Sew together at top and bottom edges. Side edges are open.

Note: the outer fabric should be extending 1” beyond the lining at the left and right edges.

Turn right side out. Press. Note: press down the raw edge of the outer layer along the seam allowance line where it extends beyond the lining.
Top stitch 1/8” from edge at top and bottom.
To make the casing for the elastic, fold raw edge of each side of outer layer 1/4” to the wrong side, then fold again so the folded edge meets the folded edge of the lining.
Stitch in place vertically, very close to the edge. Leave the top and bottom open so you can insert the elastic.
Cut 2 pieces of elastic 8” long. Pin a small safety pin to one end of the elastic to help you insert elastic into the casing. Do this on each side.

Bring elastic ends together overlapping the edges about 1/4” and stitch together. I tacked first by hand, then stitched again with the machine using a zig zag stitch. Sorry I missed taking a picture of this step! Note: Be sure to turn the elastic ends toward the lining, so it will loop over the ears when sewn together.

Slide the elastic until the seam is hidden inside the casing.

Optional Bendable Nose Piece

You can use bendable flat jewelry wire or florist wire to make a nose piece. If you use wire, bend the ends in so they’re not sharp. I had some old painting masks, so I was able to cut the bendable nose pieces off those to use on these new masks.

To make a pocket for the nose piece, mark the width of your nose piece (mine was 3”) on each side, with a small dot 3/8” from the top edge. Start at the top edge even with one of your dots, sew down 3/8” to the dot. When you reach the dot, pivot, then continue sewing a line parallel to the top edge until you reach the other dot.
Insert the nose piece from the open side.
Once you have the nose piece inserted, sew the open end from the top edge down to the dot. This will hold your nose piece in place.

If you like this pattern, please share using #stitchwerxfacemask on Facebook and Instagram! Be sure to tag us too! Thanks for using this Stitchwerx Designs pattern! Happy Sewing!

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