Homemade protective mask project/Instructions

This is a set of instructions for making your own face mask out of cotton, based on Deaconess Health's instructions and clarified and expanded.

The expansion of this to include variant construction methods (because some things, like 1/8-inch elastic, are sold out everyone) is a work in progress.

What you will need

• Cotton fabric, printed or solid-color.
  • For adults: Cut out one 9-by-12-inch piece or two 9-by-6 pieces.
  • For children: Cut out one 7.5-by-10 or two 7.5-by-5.
  • If you're working with a print, think about how the cut will frame the pattern (e.g., for licensed characters). The mask is horizontal (9-inch or 7.5-inch is the longer side), and you should cut straight across the fabric or along the fabric (with the grain).
• Two 7-inch lengths of rope elastic (beading cord elastic will work) or 1/8” flat elastic
  • OR four lengths of 1/8-inch to 1/4-inch grosgrain ribbon to use as strap
  • OR four lengths of scrap fabric turned into straps.
• A box of paper clips to use as nose-pieces.
  • OR a roll of floral wire and wire-cutters to cut it (note: beware of sharp points!).

Cutting the fabric

For an adult mask, use one 9-by-12-inch piece, folded over to 9-by-6, or two 9-by-6 pieces.

For a child mask, use one 7.5-by-10-inch piece, folded over to 7.5-by-5, or two 7.5-by-5 pieces.

Note for printed fabrics: The longer (9-inch or 7.5-inch) dimension is the horizontal dimension. Keep this in mind when choosing a portion of your fabric to cut out, especially if the fabric has a printed design with a right way up.

Two pieces is easier to work with when you're installing straps rather than elastic; it's also a way to use up fabric that isn't big enough for a one-piece mask (e.g., if you're making masks from a fabric quarter, which is 18-by-22, you can cut two 9-by-12 pieces and two 9-by-6 pieces, leaving an 18-by-4 remainder).

If you're using elastic

Cut two 7-inch lengths of elastic. If you're using beading cord, tie a knot at each end. If you're using flat elastic, don't do that.

If you're using straps

Method A: Cut four 16-inch lengths of ribbon.

Method B (requires a loop turner): Cut four 1-by-16 pieces of fabric, then fold each one over to half an inch, sew it down, and use a loop turner to turn the tube inside out. You've just made four 16" spaghetti straps.

Assembly

Phase 1: If you're using elastic

1. Put right sides of cotton fabric together.
2. Starting an inch or so from the center of the bottom edge, sew to the first corner, then stop with the needle down. Lift the foot, turn the fabric 90 degrees, and drop the foot. You should be in position to continue sewing down the next edge.
3. Insert one end of the elastic into the corner, with the end sticking out from between the pieces of fabric. The elastic between the ends should be on the inside, between the right sides of the fabric. Sew over the end of the elastic; a few stitches forward and back will hold it.
4. Sew almost to the next corner, stop, and bring the other end of the same elastic to the corner. Make sure there is no twist in it. Sew a few stitches forward and back over it, then do another 90° turn.
5. Now sew across the top of the mask to the next corner. Put in the end of the other elastic, with the end sticking out. Another 90° turn, then sew back and forth over the elastic.
6. Sew down almost to the next corner, and sew in the other end of the same elastic. Again, make sure the elastic is inside the mask and that there is no twist.
7. Last turn, then sew across the bottom leaving about 1.5” to 2” open. Stop, cut the thread.
8. Turn the mask inside out. You should have a rectangular mask with two elastic ear-pieces, one sticking out of each side.

Phase 1: If you're using straps

1. Put right sides of cotton fabric together.
2. Place each strap into a corner with the end sticking out, and the rest of the strap on the inside, between the right sides of the fabric. Do a straight stitch over it to secure it in place.
   • Each strap should be angled toward the top/bottom of the mask, but not cross it since you don't want to fasten it into that edge—it should only protrude from the left and right edge.
3. Starting an inch or so from the center of the bottom edge, sew to the first corner, then stop with the needle down. Lift the foot, turn the fabric 90 degrees, and drop the foot. You should be in position to continue sewing down the next edge.
4. Sew to the next corner, stop, and bring the other end of the same elastic to the corner and sew a few stitches forward and back. The elastic between the ends should be on the inside, between the right sides of the fabric.
5. Now sew across that top of the mask to the next corner. Again put an elastic with the edge out.
6. Sew to the next corner and sew in the other end of the same elastic.
7. Sew across the bottom leaving about 1.5” to 2” open. Stop, cut the thread. Turn inside out.
8. Pin 3 tucks (pleats) on each side of the mask. Make sure the tucks are the same direction. Each should be 3/8-inch below the one above it.
9. Sew around the edge of the mask twice.

Phase 2: Installing the pleats

1. Pin 3 tucks (pleats) on each side of the mask. Make sure the tucks are the same direction. Each should be 3/8-inch below the one above it.
2. Sew around the edge of the mask twice.

After assembly

Hygiene

Launder your masks after you finish making them, especially if you buy new supplies during the pandemic, and especially if you're giving them to others (e.g., neighbors or donating to health care providers that accept them). Don't let homemade masks become a vector.

If you machine-wash your masks, a bra bag made of fine mesh will help ensure any elastics or nose-pieces don't get caught on the machine's drain holes. Be sure to pay attention to the washing instructions on your fabrics and other parts; you may need to use cold water, and count on your detergent to obliterate and/or remove any germs.

Distribution

Some health care facilities accept donations of homemade masks when commercial PPE is scarce. Maintaining a list of such facilities is outside the scope of this article; if you can't find a current list, call up your local hospitals, clinics, etc. and ask whether they accept donations of homemade face masks.