DIY Face Mask with Filter Pocket

From:    EASY TO SEW: how to make face mask with filter pocket and adjustable wire | sewing tutorial
https://youtu.be/BCJcE-r7kcg
(video embedded below)

Please Note: I know these masks are no substitute for the medical face masks needed desperately by our medical professionals dealing with the growing COVID-19 pandemic. But in the meantime, it’s a stopgap better-than-nothing tool, whether used alone, with a filter in the mask’s pocket, or as a cover over a real face mask which people can change as they move from patient to patient.

I made these notes for myself after I watched the video (below) – I knew I wouldn’t be able to follow along just from the video. Hopefully my notes will help others working with the video.

SECOND NOTE: I have changed some things – first, several people in the video comments and elsewhere noted that the mask was not quite wide enough ear-to-ear, so I increased the fabric measurement to 8.5″ x 15″ so it’s about an inch wider when finished.

Also, I am using pipe cleaners for the nose wire, but the wire was poking through the cloth a little. To fix this: 1) I bent the ends back, so a slightly rounded end bumps up against the fabric instead of the wire, and 2) I stitched a barrier at either end of the pipe cleaner so it doesn’t slide around.

For each mask you need:

Fabric:  15”x7.5” (38cm x 19cm) or 15×8.5 for a wider mask
Bias, approx. 7” x 2″ wide (18cm x 2cm)
Twist tie: approx.. 6.5” (16.5cm)
Elastic:  2 pcs 9.75” long (25cm)

THIRD NOTE: nurses have suggested that we use two different patterns of fabric for the inside and outside, and though I already had my fabric cut for 8 masks, in the future I plan to use plain fabric for the inside, and patterned fabric for the outside. What that means for fabric dimensions is that you’ll cut two pieces, and seam them together along the 7.5/8.5″ edge (the width of the mask). That will create a two-fabrics panel which is the 15″ total measurement the original pattern calls for. But these rectangles are not the same size – the inside one is smaller than the outside fabric, plus you need to add a seam allowance.

Steps

  • If using two types of fabric (see above), seam together to create the 15″ the mask is designed for. Iron seam flat.
  • Zig zag or serge both short edges of fabric
  • Fold to bring short edges together, front of fabric on the inside.
  • Mark 1.5” (4 cm) from each edge on the zig zag edge for 7.5″ wide masks, or 2.5″ for the wider masks.
  • Stitch from each outside edge to end of mark, leaving an opening in the center.
  • Iron seams flat, turn inside out
  • Top stitch along seamed edge, making sure not to accidentally stitch to anything else.
  • Measure ½” (1.3 cm) from one side of the seam line
  • Fold at marks, and iron whole assembly flat
  • Stitch all the way around the piece, so that you leave a little opening across the “top” edge for later insertion of the twist tie, as well as the opening for the filter.
  • Bend back about 1/4″ from either end of twist tie or pipe cleaner wire so it doesn’t poke through the fabric.
  • Insert twist tie/pipe cleaner through filter pocket opening
  • Stitch across pocket so twist tie does not fall out
  • Stitch “barriers” at either end of wire so it doesn’t slide back and forth in pocket
  • With pocket-opening side down, fold mask to create 3 pleats, and iron (photo above shows approximate pleating pattern, but I’ve been adjusting it to make them more even before sewing)
  • Stitch sides to secure pleats (about 3/8″ from edge).
  • On each end of mask, place bias so one edge matches up to edge of mask, and so that about ½ inch hangs off each end
  • Fold that excess around the mask. Stitch in place.
  • Flip bias so that it hangs off the edges of the mask, not over it
  • Fold twice to make pocket for ear pieces
  • Stitch in place, leaving an opening at either end to slide elastic through.
  • Put elastics through pockets
  • Tie into a loop, and slide around so knot is inside pocket
  • Slide filter in if you have one.

Done!