Mask Pattern Download & Instructions

Deschutes Maskers

Mask Master Pattern and Sewing Instructions

1. Download Mask Master Pattern here. Be sure to print in "Actual Size" or "100% Size."
2. Choose, wash in hot water, and dry fabric(s).
3. Set out the wire that you will use for mask nose-wires (about 4” per mask).
4. If you have it, set out the narrow elastic that you will use for earloops (about 22-28” per mask, depending on adjustment method chosen).  Otherwise, skip this step for now, and post a comment letting Barb and Kate know you need earloop elastic.
5. Be confident that the more masks you make, the quicker, easier, and more intuitive the process will become. The steps below can go quite fast.

Cutting Your Fabric

1. Using the Mask Master Pattern downloaded and printed at full (100%) size, cut 4 fabric ppcs for each mask, each using the Master Pattern as template. (Picture 1)
2. Two of these ppcs will make up the mask exterior, and the other 2 will become the mask interior/lining.
3. You can use the same or different fabrics for the exterior and interior layers--it is up to you. Some believe that different fabrics for the 2 layers add interest or make it easier to see which side is which.

Picture 1:  4 ppcs to make 1 mask, all cut using the Master Pattern Download

Sewing

1. Use 1/4" seams throughout project.
2. For each mask, identify the 2 ppcs for the exterior layer, and the 2 for the interior.  Using Picture 2, also note the PPc areas, including mask bottom edge and curved center front seam.
3. Turn all 4 ppcs wrong side (WS) up.  Fold each ppc's straight bottom edge up by approximately 1/8", and then up by the same amount again.  Press to hold.  You should end up with a narrow bottom-edge hem about 1/8" high, with no raw edge showing.  Stitch the hem in place on all 4 ppcs.
4. Match the 2 interior and 2 exterior ppcs into pairs, fabric right sides (RS) together.
5. For each pair, on fabric WS, sew the mask's center curved seam.
6. Do the following to help prevent fraying during washing, as follows. On WS of mask exterior, fold both center curved seam allowances to one side. Sew the doubled seam allowances to the mask fabric underneath, keeping the fabric underneath smooth. Slightly stretching the mask fabric towards you helps flatten the curved seam allowance for sewing. Repeat for mask interior, except fold the seam allowances to the other side, to reduce bulk later.
7. Match mask exterior and interior ppcs, RSs together. Starting at one bottom corner, sew up the earloop casing edge, around the curved top of the mask, and down the other earloop casing edge to the other bottom corner. In other words, attach exterior and interior by sewing around 3 sides of the mask perimeter, while leaving the hemmed bottom edge unsewn and open.
8. The next step is to attach the nose wire. Switch machine to a medium-dense zigzag, wide enough to encase the nosewire in it. Center the nosewire at the top of the center front seam, marking in the top edge seam allowance, where the ends of the wire will rest. Then place the wire in the seam allowance, just barely above the perimeter stitching you just completed. Zigzag over the wire to hold it in place, creating what amounts to a thread casing to hold it in place
1. The ideal is for the bottom of the zigzag stitching to fall on top of the perimeter (straight) stitching, so the nosewire ends up affixed above and right next to the straight stitching. However, as long as the wire is zigzagged somewhere onto the 1/4" seam allowance of the nose area, it will work. 
2.  Begin and end the zigzag, before and after you reach the wire ends. The zigzag at the wire ends should be dense and continuous enough that the wire cannot slide out of your thread casing, from either end.
3. This may sound difficult, but it becomes quick and easy with practice.
9. Using the open bottom edge, turn mask RS out. Press. (Picture 3)
10.  Mark a centered 3" length along the open bottom edge. This becomes a hemmed opening into the mask interior, allowing the wearer to insert an optional filter layer, if desired. (Filter material is not included in this pattern.)
11. Topstitch near the edge around the entire mask, except for the 3" filter opening. Consider using a zipper foot, as it may ease passing by the nosewire area. In addition to strengthening the whole mask, topstitching finishes fixing the nosewire in place.
12. Lay mask lining side up. On one side of the bottom edge, measure approximately 4" from the center seam, and use this point to fold the earloop casing edge toward mask center. Repeat for the other earloop casing edge. On mask lining side, sew the casing in place, on top of the previous topstitching.  (Picture 4)

    

    Picture 2:  Mask PPc Areas

    

    Picture 3:  Mask turned right-side out
    

    
    

    

    Picture 4:  Mask interior with earloop casings, earloops, and "tourniquets"

Attaching Elastic Earloops, and Making Them Adjustable

1. Our prototyping showed that earloop adjustability is critical to improving mask fit on each individual. Good fit is key to reducing gaps that can let in sneeze and cough droplets.
2. From narrow elastic or stretch cord, cut 2 x 10" pieces for the earloops. Dab clear nailpolish on the ends to prevent fraying.
3. For our "tourniquet" earloop adjustment method, cut an additional 2 x 3" pieces. If you have it, consider making these a contrasting color.  Omit the nailpolish.
4. Feed a 10" elastic piece through each of the mask's side casings, using whatever tool you have available.
5. Grasp and align the 2 cut ends of one of the earloops, which are protruding from each end of the casing.  It makes things much easier if you keep these ends together by applying a quilter's clip, clothespin, small binder clip, barrette, or anything small that clips closed.
6. Take up one of the 3" "tourniquet" pieces of elastic. Below the clip, tie this around the two strands of the earloop elastic. Tie the tourniquet as tightly as you can, using a square knot (which doesn't slip). (Picture 4).
7. Trim the tourniquet ends to about 1/2". Apply clear nailpolish to them. Remove the clips.
8. Check earloop adjustability. Take an elastic earloop end in each hand (below the tourniquet), and pull them gently apart against the tourniquet. The earloop will get smaller. Make it larger by grasping the earloop sides from above the tourniquet, and again pulling them apart against the tourniquet. 
9. After you've adjusted the earloops, you might take the mask off and rotate the tourniquets and earloop ends so that they are up inside the earloops' fabric casings, out of the way and invisible. 

Legal Disclaimer:  We make NO CLAIMS that masks made with this pattern will protect you from COVID-19.  Use at your own risk.