I taught myself to sew when I was in high school and college. During a lonely Summer when I was doing an internship in nursing I spent my days with my cats sewing curtains for my apartment. I’ve sewn scrub tops when I worked in the emergency department and fleece tops and bottoms. Never did I think I would be sewing masks.
Obviously March 2020 threw me for a loop. I hauled out my sewing machine and every scrap of fabric I’d saved over the last ten years suddenly made sense. Perfect sizes for masks. I also started saving Joann Fabric coupons and buying kid friendly fabric with Frozen themes, Spiderman, Paw Patrol, etc. I ordered a lot of elastic. Some from sketchy places. I have to say though the sketchiest order I placed is the one that pulled through and delivered a large spool of elastic six weeks later.
I watched a lot of YouTube videos and read a lot of articles. I tried multiple patterns and had multiple failures. When I perfected the cotton with elastic mask I watched videos on how the filtration effectiveness of rayon blends aka chiffon are significantly higher than cotton and the closest to an N95 that fabric can make.
I bought more fabric. I had one lovely cashier who gave me 60% off my entire purchase. So much fabric.
I struggled with the chiffon. I had many failures. I actually stopped trying with two particular fabric patterns because I think they are bad luck. I literally could never make a functional mask from them. Eventually I got it though. I watched a youtube video on making a single layer chiffon mask and looked all over the craft passion website at the many mask patterns. I found that my way works best for my now 5 year olds, then 4 year olds which is a combination of many instructional videos and patterns.
The pattern is the Olsen pattern found on craft passion website.
The wire is roughly 10 or 12 gauge framing wire. About 4-6″ pieces. I cut scraps of fabric into 4-6″ rectangular strips. Then I iron them in a trifold pattern. Then I sew the piece of wire into the trifold cotton strip. If you angle the pouch correctly you can do the whole thing in one go, you kind of curve around the wire. Make sure both ends are solidly sealed because you don’t want the wire poking out. (pictures are below)
I like to sew several wire pouches at once so I have a nice stash of them. It is more efficient in the long run.
I do a double sided mask. One layer is a chiffon (rayon blend) and one layer is a character cotton fabric such as Spiderman or Frozen. For Halloween I used a pumpkin/witch fabric on top with a brown chiffon/jersey type fabric on the back.
I cut a bunch at once. I fold the fabric twice so I can cut four pieces at once- right side together. (picture below)
Then I sew along the curve of the mask pieces- 2 right sides together (pic below).
Then I take two of the sewn pieces and put right sides together, make sure center seams are aligned, and I sew the top and bottoms together. When I sew the top pieces I hold a wire pouch on and sew it onto the two pieces.
Then I turn it right side out, and fold over the edges to cover the raw edge, and form a channel that the straps will go through. Make the channel wide enough to get a safety pin through. I sew it so the “inside” of the mask is the jersey fabric, as that will be softest against the face.
The nice part about these is they are very forgiving. You don’t have to sew a perfect seam in a perfectly straight line. The more you do the faster you will be able to go, and the straighter the lines become.
So I take a safety pin, pin it through some of the chiffon/jersey fabric that I cut in thin strips along the edge of the fabric and run it through the now sewn channel. Up from the bottom for both ends. Then you should have a neck strap, and two ends at the top that can be tied around the head or I use the black buttons so kids don’t have to tie a bow they can just tighten or loosen as needed.
I’ll add a video to this. If you have questions just ask.
Below you can see finished products- I make them for me and my family and I wear mine as a double mask/top layer when I work at the hospital. Declan is running in the arcade with it hanging around his neck- that’s one of the nice parts is it doesn’t fall off. Declan as Batman has his on inside out so you can see the under seam where I lace in the fabric for around the head. My sister prefers the ear piece be around the ear with an adjuster there, so I do that kind for her and my niece and sister-in-law. My son’s and I like it around our head so it doesn’t bother our ears. You can see in yoga class I have mine tied on the back of my head, as I said the boys I use a button.