How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

How to Sew a Fitted Face Mask with Casing

Learn to Sew a Fitted Face Mask with Filter Pocket, Removable Nose Wire, T-Shirt Tie and Casing. FREE Pattern Download with 5 Different sizes from Toddler to Adult.

After many requests, I’ve updated my popular Fitted Mask pattern to include an extended tab along the edge of the pattern to create a casing. The new fitted face mask with casing pattern now includes a total of 5 sizes from Toddler all the way to Large Adult.

This post may contain affiliate links, meaning when you click the links and make a purchase, Sweet Red Poppy receives a small commission at no extra cost to you.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy.

This mask features a casing for a flexible wire nose piece and a liner pocket so the wire and liner can be removed before washing. It also features a more secure fit with the side casing and adjustable t-shirt tie.

*Please use caution when using the Toddler size, this pattern is not meant to be used on children under the age of 2 as it may pose a breathing hazard. Children should be supervised by an adult while wearing a mask.

First off, let’s talk a little bit about fabric. You should use a 100% cotton fabric for this fitted face mask. This is a natural fabric that is breathable and it tightly woven. You can place a non-woven liner inside the mask for added protection ( I use a coffee filter).

JOANN has a wide variety of quilting cotton that works perfectly for this mask and they are available at an affordable price tag!

I’ve also found high-quality designer quilting cotton on Etsy that works well but they do have a higher price tag. The upside to Etsy is the shipping is generally faster.

I recommend purchasing fabric by the 1/2 yard as this will allow you to make several masks from your fabric. 1/4 of a yard (9″ of 44″ wide fabric) will yield 6 adult mask pattern pieces or 1.5 finished masks.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Prewash and dry your cotton fabrics before sewing them to prevent the fabric from shrinking or bleeding.

DOWNLOAD THE PATTERN HERE

SUPPLIES NEEDED FOR YOUR FITTED FACE MASK

Step 1. Print the Fitted Face Mask Pattern.

Begin by downloading the pattern to your desktop. Open the download, and print at 100% with no scaling. Immediately measure the 1″x1″ square to make sure the pattern has printed off correctly.

Step 2. Cut Out Main, Lining, Casing, & Tie Fabric

Select your desired size and cut out the mask pattern piece. If you plan on cutting out multiple masks, you can cut the template out of something sturdier like a cereal box or cardstock.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Lay the fabric out in front of you. Cut out a mirrored set of fabric from your main mask and for your lining.

You should have a total of 4 pieces of fabric.

*Optional- Cut out a 6″ x 1.5″ piece of fabric to create the flexible nose wire casing.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Cut a 1″ wide strip of t-shirt material to create the tie. Stretch the t-shirt circle and cut one side off to create a long strip.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

You should have two main mask pieces, two lining mask pieces, a t-shirt tie, and a casing.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Step 3. Press & Sew Casings

Take the main fabrics (pink) and press the short edge under (wrong sides facing) 1/4″, fold over and press under an additional 3/4″.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Take the lining fabric (green) and press the extended tab under 3/4″. Fold inward and press an additional 3/4″. Sew along 1/4″ from the folded edge.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

When placed together the main and lining folded tabs should meet each other.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Step 4. Sew Main and Lining Fabrics

Place the main mask pieces right side together and pin. Repeat with lining.

Sew the main and lining along the curved edge using a 3/8″ seam allowance.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Open the masks and press the seam allowance to the left. Topstitch 1/4″ from the middle seam if desired.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Press the wire casing 1/4″ under on the top and sides leaving the bottom open.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Align the raw edges of the casing with the raw edge of the lining (wrong side of casing facing the right side of mask) and pin in place.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Place the main mask on top of the lining with the right sides together.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Sew around the top and bottom of mask, making sure the main fabric extended tabs are open.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy
How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Step 5. Turn Right Side Out & Topstitch

Turn the mask right side out. Roll out the seams and press.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Topstitch along the folded edge of the casing, leaving the short ends open.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Topstitch around the entire mask 1/4″ from the edge.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Create the casing by folding in the extended tab. Sew along the innermost fold to secure the casing in place.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy
How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Step 6. Thread T-Shirt Casing

Cut a piece of wire slightly larger than the casing. Turn the sharp edges inward on both sides.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy
How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Insert the floral wire into the casing. Now it can easily be removed before washing the mask.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Attach a safety pin to the t-shirt tie and feed upwards it through the right-hand casing and downwards through the left-hand casing. The tie can be adjusted once it is placed on the wearer for a better fit and tied at the base of the neck.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy
How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Don’t forget to join my face mask Facebook group where you can show us what you’re making, ask questions, and learn from others! Follow me on Instagram for daily crafting inspiration and a look behind the scenes.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy: Fitted Face Mask with Wire Casing and Filter Pocket and T-Shirt Ties

Place your fitted face mask onto face, the top strap should be placed high on the head and the bottom ties should be tightened around the base of the head.

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

Download the Printable Tutorial Here!

How to Sew a Fitted Face Mask with Casing, a tutorial featured by top US sewing blog, Sweet Red Poppy

To view more of our sewing tutorials, click here!

*Disclaimer- Homemade masks will not prevent someone from becoming infected with Covid-19. They are approved by the CDC to be used as a last resort when all other PPE options have run out.  Health providers experiencing shortages, who have handmade masks can use them on lower-risk patients allowing N95s to be reserved for emergency cases. This fitted face mask tutorial post is in response to pleas from hospitals for handmade masks.

98 thoughts on “How to Sew a Fitted Face Mask with Casing”

  1. Thank you so much for this tutorial. It’s like you read my mind! Everything I’ve been struggling with: adding the wire, adding a filter pocket, getting comfortable ear ties (love the t shirt idea!) and being able to tie them without slippage, has all been covered in this video. I’ve been watching so many videos and finally this is exactly what I’ve been looking for. I can’t wait to try this tomorrow!

  2. Thank you for posting this. I like the wire casing and the tie casings on this one (less bulk). Will there be a condensed version suitable for printing?
    In the video of the fitted mask with paracord/t-shirt tie there are 3 layers of fabric with a pocket opening, inside, center. I assume that proved to be a weak spot for germs? Thanks again.

  3. Could you include a link to the mask template? I printed it out earlier but now cannot find it and need to print on cardstock. TIA

  4. Bonnie Zeanchock Bashista

    I cannot obtain the newest pattern. Any assistance would be appreciated. I have the older pattern but not the newest on that the tutorial is based on.

    1. I am not able to get the updated pattern either. Has anyone found a link yet for it? if not, can one please be posted? Thank you!!

  5. HI, This is my first time making masks and I haven’t sewn in years. Can I use ribbon instead of t shirt? They are just for family and friends. thanks!

  6. thank you for sharing this info, I’ve been up and down the website and is there not a way to save the instructions?

  7. Are you cutting the same pattern for main fabric and lining? If so, when you press each according to directions, the folds will not meet like the pic because you are folding back a total of 1″ for both lining (1/2″ + 1/2″) and main (1/4″ + 3/4″). In the next pic, it looks like you folded over the lining again after sewing that fold shut, so maybe that’s a missing step or am I misunderstanding? Love all your patterns. I made this particular pattern a few days ago (in the adult large for a friend) with the previous directions of folding both lining and outside over together for the casing. It has the best face fit and breathing space of any others I’ve tried!

    1. To clarify the folding: Lining (green) is folded in 3/4″ and then another 3/4″ = 1 1/2″ total folded in (& edge-stitched at 1/4″. The main fabric is folded 1/4″ and then again 3/4″ = 1″ total folded in. So, the main fabric will extend an additional 1/2″ beyond the lining. Hope that helps!

    2. I’m also struggling with figuring out these measurements…and they seem to be different than in the video? Is there a typo?

    3. I also have this question. In the video it seems clear that the inner edge of the fold for the mask front is supposed to sit just flush with the outer folded edge of the mask lining. The mask front is folded 1/4″ + 3/4″, for total of 1″ folded back from its original position. Because the second fold is 3/4″, that inner edge of the fold on mask front sits another 3/4″ in, so a total of 1 3/4″ over from its original position. For the outer folded edge of the mask lining to sit flush as seen in the video and photos, it must reach a total of 1 3/4″ folded back from its original position. Neither the video (1/2″ + 1/2″) nor the blog (3/4″ + 3/4″) instructions would achieve this.

      The first time I made one of these I solved by changing mask front folds to 1/4″ + 1/2″, and doing 3/4″ + 3/4″ on mask lining. The resulting narrower casing is a little snug for the straps, but works ok. Second time around I am solving by doing mask front as written, but making 3 folds on mask lining: 1/2″ + 1/2″ + 3/4″. I will post results on the Facebook group when I’m done. But it would be great to have this issue clarified in the blog, video, and printable versions of the pattern.

    4. Kerry: Main fabric is 1/4 +3/4 the lining is 3/4 + 3/4. You could always do one and then make the other line up. I had trouble with that also and had to reread it a couple of times before I got it. Lines up nicely now. Hope this helps

  8. Sorry, I should’ve watched the video before writing. I understand what you did now. You can delete these posts of mine so they doesn’t confuse anyone.

  9. Kimberly, these are the best yet! Thank you! I’ve made over 110 masks now, all from your various patterns and was just starting to adapt to this type, but now you’ve made it all so much easier and faster. Thank you!!!!

  10. Thanks for the tutorial and pattern. I added a fusable light/medium interfacing to the outer fabric. It gives the mask more stability plus a extra layer of protection.

  11. I would thread the ties the opposite way. If you have tried to tie this, it is easier to put the loop around the back of your neck and pull the ties to the top of your head for tying. Thanks for the tutorial .

  12. Thank you for a new approach to the nose wire casing! I’d seen one on a pleated mask tutorial, but I’m making the curved style. For the past week I’ve been putting this style of casing in between the wrong sides of the mask and lining. I like your approach better. I highly recommend cutting the wire casing piece on the bias so it will bend better on the curve of the nose.

  13. Do you have a .pdf of the instructions? Thank you for helping us all learn how to make these. This one is just perfect. Thank you in advance

  14. Do you have a condensed version like with the other 2 Face Masks patterns. I really like the T-Shirt tie idea and was hoping I would not have to print 30 pages to get the instructions. I have made lots of your fitted mask and have had great comments. Thank you so much.

  15. Thanks for the latest Mask pattern. Unfortunately working in a Correctional environment forces me to wear a mask 12 hours at a time. Looking for a pattern or could one of your patterns me modified to allow one strap above the ears to allow for better neck movement (two levels and always having to look up). Again, Thanks for the instructions and patterns.

    1. Yes! Use the previous pattern that utilizes bias tape or ribbon to see how the straps might be sewn in place. You might also want to make the portion near the ear a little taller. (I have had to do that with the previous pattern because the ear straps wanted to go around the neck, especially in the child pattern.

  16. What are the ages for the sizes? I am making masks for military family members and you pattern is the best one I tried but I don’t know the ages for the kids masks! Thanks

  17. Is it posible to download the instructions without all the adds? Huge amount of printing and paper. THANK YOU for this tutorial!

    1. I have been making strips (almost like bias tape) with my cotton fabric just make it 40 inches or 42 inches and then use a crochet hook to get them into the mask!

  18. I’ve made the pleated one and your basic one (love that, it’s so easy) and tried the pocket one with the opening in the back seam but struggled with that. I’d love to try your new pattern since it combines what I need to make for local first responders . I am not able to find the pattern on the site. Many thanks,

  19. Linda Wachowiak

    Are there printable instructions somewhere. I printed the template but would like written instructions. Thanks.

  20. Kimberly, is it possible have this pattern loaded to Cricut to allow me to cut the pattern with my Maker? I’ve made several of your masks and the patterns/instructions are the best.

  21. Sandy Hardcastle

    Thank you for the pattern and the easy step by step video. I appreciate the time you spent putting it all together for us. I’m happy to have a worthwhile project to share with those who need a mask. Sewing is my favorite pastime, plus I’m using all my scraps that bring memories of all my past projects.

  22. Thank you for the pattern and the easy step by step video. I appreciate the time you spent putting it all together for us. I’m happy to have a worthwhile project to share with those who need a mask. Sewing is my favorite pastime, plus I’m using all my scraps that bring memories of all my past projects.

  23. Thank you so much for this tutorial. I love the whole idea of the pattern. I love that it only ties once and has a nose wire casing. I used bias tape to save some time. I wish you had a photo of it on a person. I made the ADULT size and it is too small. I am not a large person. It doesn’t go under my chin. I will be making the large adult size in hopes that it will fit differently. Thanks again.

  24. I think there is one mistake in the instructions. You say to sew around the entire mask. But actually, you are sewing just the top and bottom, not the sides.

  25. I’ve made a similar mask, but wondered if the t-shirt ties should tie on top of your head instead of below the chin. And if you’re lucky enuf to have elastic, one continuous piece with ends sewn together works, too. I found this shape of mask fits the face well, but gives room to move your lips and breathe.

  26. It took me at least 10 minutes, but I found the pattern link. It’s right above here: SUPPLIES NEEDED FOR YOUR FITTED FACE MASK. Very challenging to find.

  27. Do have any information on making a filter to fit this mask?
    Use the pattern piece? Cut smaller?
    Thank you.

  28. Can you post some pictures of a person wearing the mask with a filter and T-Shirt ties to get a better image of what it is supposed to look like when it’s done? Thanks!

  29. Carol Marszalek

    I have been making this mask for the military and family/friends with a few differences. First, I have seen in Hepa vacuum bags as washable permanent filters. It is too difficult to try to insert removable filters and I found folks just don’t mess with it…….Second I sew in batting wrapped copper wire that can be washed. Third, My linings are either musing scrubs or a copper infused ICU bed sheet. And finally, my cords are Paracord 325 and I thread them opposite of what you do, that way when not needed (ie. Back in the car between stops, the mask unties from the top and can lay on the chest until next needed.

  30. is there some way I can have this pattern for this mask mailed to me. I don’t see anywhere to get the pattern would be willing to pay for it, The fitted one with ties made from t shirts,

  31. I can’t get the pattern because it says my email address is not valid. No one else has any issue with it….
    What can I do? I don’t have other addresses to use.

    1. therese, if you copy/pasted your email address or chose it as it “popped up”, it might not work. Try typing the whole thing.

  32. Hi Kimberly,
    Is this pattern compatible with design space? I’m a newbie but I wanted to use my cricut maker and make these mask. Any help you can give would be a blessing.

    Thanks so much!!

  33. This might seem like a dumb question, but would you adjust the folds and casing for the smaller sizes? I tried a child sized with the given instructions, but it just doesn’t seem right.

  34. Scrolling. Scrolling. Haven’t been able to find a video yet I’m trying to decide how that fits over your head or does it tie in both places because on the photos it looks like it loops and I can’t tell how you wear it.

  35. I’ve seen other videos where the maker uses clips instead of pins so that you don’t risk poking holes in the mask that would be large enough to allow the virus/bacteria to get in or out. Thanks for this pattern and very thorough instructions. Love the pocket to remove the wire for washing — great idea!

    1. Then again…. if pinholes were that big of a deal, why is it ok to sew a center seam, leaving needle holes. Sorry. Just thought that one through… duh.

  36. This is awesome! I’ve been wondering how best to do a nose wire pocket. I’ve been using your original pattern and instructions and this is fab

  37. Tommie Shelton

    Threading the t-shirt tie with it tying at the neckline, my son finds the t-shirt tie and the band not tied on the head more comfortable with a hard hat.

    1. The link for the pattern is just above the list of Supplies it is written in Light Blue

      DOWNLOAD THE PATTERN HERE
      SUPPLIES NEEDED FOR YOUR FITTED FACE MASK

  38. Thank you sooo much for this pattern!! I made two and use them at work. They actually fit my face and stay in place. Thank you!!

  39. Jacqueline Delano

    Thanks for the pattern, I like this one. My only question is how long of a piece of the 1″ Tshirt material do I cut for the tie?

  40. Thank you very much. Your procedures have been fairly straightforward for a person who has not sewn before.

    Can 1/2 inch single fold bias tape be used with this one like the previous edition?

    What is a good technique to determine the correct size for a person?

  41. Tamara Davis

    I had downloaded one of your patterns a couple weeks ago but I don’t think it had the nose wire casing piece or the filter and had been watching videos trying to find what would be an ideal method and wasn’t finding anything I felt simple enough. Your’s is perfectly what I was looking for! Thank you for sharing this!

  42. How would you choose between child and toddler size? I want to make one to make one for my nephew who is five.

  43. Love this pattern with the exception of the filter. I am having a terrible time figuring out the filter. Size? But more importantly how in the world do you get the filter inside so it lines up and is effective? I haven’t found a method that remotely works. Please help!

  44. Pingback: Sew a Fitted Face Mask with Removable Wire Casing, Filter Pocket, and T-Shirt Tie! – Face Mask Casa

  45. Julie S Betzel

    This is by far the best pattern I have used. I use elastic and 40 inches seems like a lot but it’s very comfortable and I love that you can keep it around your neck when you aren’t wearing it.

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