We are making a fabric pocket mask with fabric ties. This face mask was designed by local sewer extraordinaire Jeni Falldine.
Disclaimer: These do not meet the medical standards for surgery, and are meant to be the best solution with off-the-shelf materials to create an effective viral barrier. We have consulted doctors and virologists, materials experts, and makers. We’ve reviewed many plans, produced 3 iterations and the 5-Layer Facemask is the best solution we’ve found, especially where replacement masks are scarce.
Update: Due to a shortage in elastic, and more information on the ideal masks for long-term use, we are changing the type of mask we recommend you sew. We are following the guidelines set forth by the Million Mask Mayday group on Facebook.
This will work great as a standalone 2-layer mask, and provide the option to insert additional barrier layers. Seattle Makers will be receiving 3-4 large boxes of non-woven fibers that we will cut into barriers for these masks and delivering alongside the masks to appropriate hospitals.
We will be providing kits for this mask at Seattle Makers. If you are interested in helping with this project you can pick one up and follow the instructions below. We also have sewing machines set up in a socially distanced, sterilized production area with mask and glove protection. Email [email protected] if you are available for sewing here at the makerspace or at home.
Note: Some fabric stores in our area (Seattle) are closing for 2 weeks effective immediately, so buy materials now if you are still able. Please let us know if you have extra materials, we will be distributing kits to as many people as possible.
- 100% Cotton, tightly woven (this is important)
- 1 x Rectangle 8”x15”
- 4 x Strips 2”x 15”
- OPTIONAL: Wire – 18-20 guage soft wire for close fit around nose (NOT recommended for health care professionals working around MRI machines or other machines that are sensitive to metal)
- OPTIONAL: Wire Cutter
- Sewing machine
Making the fabric ties
Step 1. Start with a 2” wide strip (shown in Image 1) and iron it flat with the outer fabric (pretty side) down.
Step 2. Fold the two raw edges in to meet in the middle, making a 1” wide strip. Then fold in half again to make a ½” wide strip. All the raw edges will be folded to the inside (Image 2).
Step 3. Stitch the open side closed 1/8″ to 1/16″ from the edge (Image 3)
Making the Mask
Step 4. Take the large 8″ x 15″ piece of fabric, and finish the opening of the pocket with a 1/4” rolled hem. First fold the top edge down 1/4″ and press it. Then fold the folded edge down 1/4″ again and press it (Image 4).
Step 5. Sew the top edge shut (Image 5)
Step 6. Repeat this process with the bottom edge (Image 6).
Attaching the top ties
Step 7. Attach the left top tie to the outside face of the fabric (the pretty side). You will pin one end near the raw edge leaving the free end of the tie toward the center, about 1 1/4″ inches from the top hem (Image 7). Repeat for the right top tie.
Step 8. Pin the bottom left tie 6.5 inches from the bottom of the fabric in the same fashion as in Step 7, the majority of the tie towards the inside (Image 8).
Step 9. Once all your ties are pinned, tack them in place 1/16” from the raw edge with your sewing machine, and remove the pins (Image 9).
Step 10. Arrange your ties in a neat bundle in the middle of your mask, so you when you sew up the sides they don’t get caught in the seam (Image 10).
Step 11. Fold the top hem down 1” (Image 11).
Step 12. Fold the bottom hem up to overlap the top hem (Image 12). We aligned the bottom rolled hem with the top rolled hem.
Step 13. Place pins in the four corners to hold the shape in place: two where the hems overlap, and two near the bottom fold.
Step 14. Sew up the side seams, making sure the ties stay out of the way (Image 14).
Step 15. Remove the pins. The sides will be sewn but there is an open slot at the top of the mask that will allow you to turn it right side out in the next step (Image 15).
Step 16. Turn the mask right-side out through the opening slot shown in Image 15. You may need to poke a pen or scissors into the corners to push them all the way out (Image 16).
OPTIONAL: aDDING THE NOSE BRIDGE WIRE
Note: this section is optional. Wire should NOT be used in face masks for health care professionals who work around MRI machines or other machines that are sensitive to metal. If you don’t want to add the wire, skip this section and jump to Finishing the Edges and continue with Step 22.
Step 17. Cut a 3.25” section of wire for the nose bridge (Image 17).
Step 18. Set the cut section of wire centered on the top, near the fold, and mark the left and right sides with pins (Image 18).
Step 19. Place the wire inside the fold (Video 19).
Video 19. How to insert the nose wire.
Step 20. Stitch closely around the wire to create a pocket. Make sure to back-tack several times to keep the wire in place (Image 20.
Step 21. Look! It’s a wire in a pocket! (Image 21).
Finishing the edges
Step 22. Press the edges with a steam iron, and top stitch closely (1/8″ to 1/16″) around the entire perimeter, going over the side seams twice (Images 22a and 22b)
Step 23. You’ve got a smart looking mask (Image 23)! You could add 4 more ties at this point and it would really look like a squid. Resist that urge.
Adding 3 pleats
Each pleat will be 1/4″ to 1/2″ in depth, so the finished mask is about 4” in height.
Step 24. Start your first fold as close to the bottom tie as you can. You want your pleats closer to the bottom than the top. There is some room for variability here. You can see where we placed each pleat in Image 24.
Step 25. After each fold, press with the iron (Image 25).
Step 26. Top stitch the sides again to tack down the pleats.
Finish the tie ends
Step 27. Fold the end of one tie over twice (Image 27), and press. Repeat for all four ties.
Step 28. Topstitch about 1/8″ from the edge of the tie to finish (Image 28).
Step 29. If you have non-woven material like dryer sheets, insert 2-3 layers in your face mask to add extra air-borne disease protection (Image 29)
Step 30. If you added the nose wire, bend it nose wire and you’re done! (Video 30). If you didn’t add the nose wire, you’re still done!
Video 30. Bending the nose wire.
Second option: Instead of fabric strips, you can use elastic if you have some available (Image 31).