DFW COVID PPE Sewing Relief Group Mask Sewing Guide Vs 1.

Website: http://dfwsewingrelief.org/ Email: info@dfwsewingrelief.org

Facebook: @DFW COVID PPE Sewing Relief Group

We have worked hard to research the various mask patterns and talk with healthcare providers in determining
this mask pattern is best for the needs of our healthcare community at this point in time.

We will continue to evaluate the needs and uses of our masks and may need to make changes to this pattern
based on feedback from our users. We will also update this pattern to improve the clarity of the instructions.

There will be a video tutorial that matches this process coming shortly. Watch our FB page for updates.

Supplies:
• 100% cotton fabric, preferably a dense weave like is found in quilt fabric.
NOTE: DO NOT use polyester, cotton-poly blend, knits or any type of synthetic fabric.
• Elastic / Fabric Ties – 1/8” or ¼” elastic, or fabric ties on each corner. Ties can be fabric bias ties, bias tape,
twill tape, ribbon, etc—basically anything where the ends can be finished to not fray
• Interfacing (optional) – lightweight interfacing, fusible or non-fusible
• Craft wire: Craft wire or chenille stems (any type but preferably strong enough to “hold” in position over
the nose. Chenille stems, pipe cleaners, florist wire, twist ties can also be used. See directions for how to
secure the various types of nose piece wires in Step xx
• Sewing machine and general sewing supplies

PLEASE NOTE:
Video link: The video link at the end of these instructions provides ideas for making ties as an alternative to
elastic, as well as using a serger or wide, close zigzag for the seams. Please use everything else as outlined in the
pattern below so we can have masks that are as uniform as possible.

Fabric – 100% Cotton: Please ONLY use 100% cotton fabric for the masks. If you are not completely sure your
fabric is 100% cotton, please be on the watch for an email announcing our mask kits which will all have only 100%
cotton fabric.
Interfacing: If you have interfacing available this will provide more protection to the mask than fabric alone.

Nose wire: We have found that craft wire (16-20G) works better for the nose piece but if using florist wire or
twist ties you will need to double the wire to provide a more substantial “fit” over the nose.
Let’s Get Started!

• Cut 2 - 9” x 7” pieces from 100% cotton fabric

Note: it is preferred that 2 different fabrics be used so as to tell front and back
• Optional: Cut 1 – 9” x 7” Interfacing, Lightweight (fusible or non-fusible)
• Cut 2 – 2” x 6” pieces from 100% cotton fabric (this can be the same as one of the mask fabrics)
• Cut 2 – 6” strips of elastic
Note: if using fabric or ribbon ties, cut 4 – 18” ties
2” x 6” x2 fabric
• 1 – 6” piece of soft wire with ends bent (sides)
6” x 1 craft wire
inward (chenille stem, craft wire, florist wire,
(nose piece)
6” x 2 elastic
twist tie)

9” x 7” x 2 fabric
(mask front / back) 9” x 7” x 1 interfacing
*Optional
(mask lining)

18x 2 fabric, bias, or ribbon

for ties if not using elastic

1) Create mask front / back.

Sew 9” x 7” fabric right sides together using a ¼” seam on the long side (9”) Pic 1. Repeat for the other 9”
side. Pic 2—without interfacing; Pic 3—with interfacing

Pic 1 Pic 3
Pic 2
If you are using interfacing, place the interfacing on the wrong side of the mask front fabric. Pic 3.
 Turn right side out and press, taking care to make sure the
seams are smooth.

2) Creating pocket for nose piece.

Sew between 1/4” - 3/8” top stitch from the edge on both sewn sides (9” side) to form a narrow pocket.
The pocket needs to support the craft wire / chenille stem / twist ties that you are using for the nose
piece.

Front Back

3) Add wire to create nose piece.

Cut 1 – 6” craft wire and fold in ends to form small loop using small (needle nose) pliers. Use pliers to
slightly flatten each loop to ensure no sharp ends are poking out.

Use 1 narrow pocket to load the craft wire for the nose piece. You will probably need to use needle nose
pliers to make the loop as small and close to the main wire as possible.
Use fingers to position wire in the middle of the mask. There will be approx. 2” on either side of the wire.
 If using chenille stems, florist wire, or twist ties you will
need to adjust the pocket based on the width of the wire.

Example to the right using a chenille stem:

First picture, notice how the ends are bent such that then
lay flat against the stem as in picture 2

4) Adding mask pleats.

Pleat the fabric. Make 3 narrow pleats in the mask, with pleat folds facing “down” from top of mask (with
wire) to bottom of mask.

You will be pleating both

layers of fabric—front and Front of mask –pleats face Wire is top of mask
back downward from top of mask

Pleats should start 1 ½ to 2” from top

(wire edge) with each pleat being
approx. 1/2“ wide

Adjust pleats to be approx. equal. Use

pins or clips to hold pleats in place and
sew across pleats down using a ¼” seam. Back of mask
Report on both sides of mask.

Side of mask with pleats

Sew along the short side of the mask. Repeat on the other side.
Be sure the catch all layers of the pleat when sewing.
 Here is what the front of the mask should look like at this point.

Front of mask Top of mask with wire

5) Attach the ties or elastic.

Clip or pin either 6” elastic or 18” ties approx. ½” from top and bottom edge of all 4 sides.
Be sure the elastic or ties FACE IN with the edge of the tie or elastic even with the edge of the mask. side
of the mask,

Sew approx. ¼” from the raw edge. Backstitch across the elastic or ties to secure to the mask.
 Here is what the front of the mask should look like with ties (or elastic) attached.

6) Finishing the Edges of Mask:

Take each 2” x 6” piece of fabric, fold in half along the long side, press.

Center and pin the folded 2” x 6” strip along the short end of
the mask, matching raw edges, on the front side of the mask.
You will have approx. 1” overhang on each side.
Fold the extra fabric around the mask edge and clip or pin
to secure.

Sew ¼” from the edge from the front side of the

mask, making sure to capture the flaps on the
underneath side of the mask.

Be sure to keep the elastic free from the area

being sewn.

Front of mask

Back of mask
 7) Flip the fabric cuff up, and then fold the
front of the cuff over to the back of the
mask, covering the raw edges of the cuff.
Pin to secure in place, making sure to tuck
the raw edge ends completely under the
cuff.

Back of Mask Front of Mask

Back of Mask
Sew close to the edge of the cuff, backstitching on each edge to secure.
Repeat for other side.

Front of Mask Front of Mask

Back of Mask Back of Mask

 Ta Da! You have finished a mask! Congratulations and THANK YOU!

Please send any questions to: info@dfwsewingrelief.org

Video tutorial of this process is coming to the DFW COVID PPE Sewing Relief Group FB page soon.

REMEMBER
Please use ONLY using this pattern above for the masks.
The link below shows how to use a serger or a wide, narrow zigzag for Step 1. It
also shows alternative materials to use for ties, if you don’t have elastic,
but IS NOT intended to replace the pattern above.

https://www.youtube.com/watch?v=L55CNVm2FXw&feature=youtu.be