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.
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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.
Prewash and dry your cotton fabrics before sewing them to prevent the fabric from shrinking or bleeding.
Before cutting out your pattern, review the graphic below. This will help you to choose the correct pattern for your specific face shape. The best way to do this is to take a photo of your face from a side angle and draw a line along the front of your face. If the line is a vertical line version 1 will fit you best. If the line goes inward along your chin, select version 2.
SUPPLIES NEEDED FOR YOUR FITTED FACE MASK
- Sewing Machine
- Quilting Cotton
- Scissors OR Rotary Cutter & Cutting Mat
- Safety Pin
- Iron & Ironing Board
- Sewing Pins
- 22-24 Gauge Floral Wire (Optional)
- Wire Cutters (Optional)
- Jewelry Pliers (Optional)
- New to Sewing? Check out my Beginner Seamstress Supply List on Amazon here!
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.
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.
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.
You should have two main mask pieces, two lining mask pieces, a t-shirt tie, and a casing.
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″.
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.
When placed together the main and lining folded tabs should meet each other.
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.
Open the masks and press the seam allowance to the left. Topstitch 1/4″ from the middle seam if desired.
Press the wire casing 1/4″ under on the top and sides leaving the bottom open.
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.
Place the main mask on top of the lining with the right sides together.
Sew around the top and bottom of mask, making sure the main fabric extended tabs are open.
Step 5. Turn Right Side Out & Topstitch
Turn the mask right side out. Roll out the seams and press.
Topstitch along the folded edge of the casing, leaving the short ends open.
Topstitch around the entire mask 1/4″ from the edge.
Create the casing by folding in the extended tab. Sew along the innermost fold to secure the casing in place.
Step 6. Thread T-Shirt Casing
Cut a piece of wire slightly larger than the casing. Turn the sharp edges inward on both sides.
Insert the floral wire into the casing. Now it can easily be removed before washing the mask.
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.
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.
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.
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.