Follow my face mask free pattern and learn how to sew a face mask for your personal use! My detailed step by step tutorial will teach you how to sew a face mask with filter pocket and nose wire!
With the whole world being in a time of distress about the coronavirus spreading I thought it would be a good idea to learn how to sew a surgical face mask. Also, it will make my kids and myself productive since we are practicing self-quarantine in hopes of not getting the virus. Secondly, my Surgical Cap And Mask Pretend Play Free Pattern post, recently was getting many page views, so I thought I will design a face mask free pattern to use in real life.
Some people debate that these masks are a preventative step in not catching this disease. Others say that these masks are only good for stopping the spread of this disease, as they catch water particles coming out of a sick person’s mouth when that person coughs. It is for you to decide what side you are on.
I shared my, DIY surgical face mask free pattern with a filter pocket tutorial with my long time nurse friend and asked for her opinion. Her response was that more layers in the mask, the better it works. Also, since the mask it’s made out of fabric it needs to be washed in a hot water cycle after each use. It is my personal belief that it is better to have something versus nothing when going to public places during these times. It may not be as good as an N95 mask but at least it offers some protection.
Shortly after I posted the DIY surgical face mask tutorial, I got requests from my readers to design a scrub cap pattern. It makes me very happy and thankful that so many people are helping to restock the inventory for hospitals. So, here it is, my detailed step by step tutorial and free template for a DIY surgical cap.
Let’s get ready to sew a face mask with a filter pocket!
So, I designed this DIY surgical mask free pattern to have the ability to add more layers and make it more effective. You will need about ¼ of a yard of quilting fabric or pre-cut fat quarters would work perfectly for this project. Also, you can use this same fabric print for both sides of the mask or different prints for fun. This post contains some affiliate links for your convenience (which means if you make a purchase after clicking a link, I will earn a small commission but it won’t cost you a penny more)!
The opening on top of the mask is to slip in some tissue paper in, to make more layers, and also, you can sprinkle the tissue with some of your favorite essential oil. I think doing so, makes the outing in the mask more enjoyable while sniffing in your favorite scent. CDC guidelines state that you can use coffee filters as an additional layer in your hand made face mask.
While going through the DIY surgical face mask free pattern tutorial you will find a step where I used pipe cleaners. I think it’s a great idea to make the top of the mask fit to your face.
All of the materials for the DIY surgical face mask you are able to buy at your local Joann Fabrics or Hobby Lobby. I made a list to buy everything online if you chose to order online without leaving your home.
And, always wash and dry fabric ahead of time to pre-shrink it.
What You need to sew a face mask with filter pocket
If you will be steam sterilizing the mask it would be better to use gauge or floral wire for the nose clip. The pipe cleaner fibers may melt in high heat.
Are you ready to learn how to DIY a surgical face mask with a filter pocket?
Step 1. Cut two 8×12” rectangles out of the cotton fabric and for child-size face mask cut two 6.5×10.5” rectangles.
Step 2. Have one long edge of each piece fold ¾” to the wrong side and stitch using a zig-zag stitch. Doing so, you make casings to slip in pipe cleaners in later.
Step 3. Now, pin those two pieces right side together and stitch the other long edges together.
Step 4. Iron the seam flat to one side, pin the casing edges together, and iron the seam flat from the right side.
Step 5. Stitch very close to the edge on the casing long side, about 3.5” from both sides.
Step 6. Take two pipe cleaners, bend and then twist both edges to the size of 8”. And for a child size mask make the pipe cleaners 6” long.
Step 7. Slip in the pipe cleaners to each casing and finish the short edges using a zig-zag stitch.
Step 8. Fold the short edges 3/4” to one side and stitch, doing so you made these casings to slip the elastic in. For adult size mask you need 24-26” long elastic and for a child-size mask 16-18”.
Use a safety pin to slip in the elastic into the short edge casings and then tie a knot with the elastic. You can also shift the knot to one of the casings making it invisible.
OR
Step 9. Cut two 8” long, 1/8” wide elastic and slip each through side casings. Tie the end of elastics together and shift the knots inside the casings. Now, you have a DIY surgical mask with elastic loops that you wear over your ears. For kids size DIY surgical mask cut two 6.5” long, 1/8” wide elastic.
Now, make a stitch on both sides of the mask to keep it in place on the elastic. And, that way the fabric won’t shift while wearing the face mask.
And, done!
My son Daniel is modeling for me today. You see the two ways that you can make and wear the face mask.
I hope you will find my DIY surgical face mask free pattern useful and easy to follow. You are welcome to post a picture of your face mask on my Facebook page and also on Twitter.
Sue, I’m glad you like my face mask tutorial. I have washed and dried my masks several times and the pipe cleaners are fine. You may need to straighten them out but otherwise they worked for me. Also, I have found wires for the nose on amazon, you may want to get those.
Hi – I don’t do much sewing but made the mask after a few mistakes – your tutorial was excellent- thanks so much – saw some elastic for sale but now can’t find it?
There are so many comments I may have missed the answer to my question. What’s the best way to wash the mask? With the wire in it and the elastic exposed I want to wash it properly so it lasts. Thanks for posting these directions!!
Sara, I was thinking once it was washed/disinfected & I had different patterns on each side allowing the person to choose which pattern/side they would like to wear. Especially kids…i. e. stars on one side super hero’s on another Or solid on one side pattern on the other for adults. They could only change sides after it being washed, not while wearing it. I’m assuming that would be ok.
Thank you for this pattern. I have made a similar pattern that you use Paracord with a loop on bottom for neckline and then tie at back of head. I love your elastic around the head better! Now to find elastic in my stash as it is not available in stores.
Hi, I would not use a tissue as a filter it gives no protection! The best thing to use is the blue shop towels. they are ”hydrophobic”, which means they don’t absorb water or virus! Cut them to fit your pocket and use two layers. My son has a masters and works in this field. Google it if you like!
Gaile,
Thanks for your comment/suggestion.
I was planning to contact 3M tomorrow to inquire about the components of the “blue shop towels” since I saw an article recommending them as face mask filters due to their good filtering ability, but I can’t imagine that towels used for workshop or car cleaning would also be “pure” enough to be breathing through. Can your son give any info regarding that?
They are certainly cost friendly. Thank you for your further input.
Is it possible to use old jeans for the material since it is a heavy type of material? I have a lot of those and was going to make a quilt but could use it for this. Just if you think it will work. Thank you so much for the pattern and instructions.
Thank you so much for this pattern. I am a RN on our hospital’s Covid unit and I now have to wear a cloth mask all the time at work when I’m not wearing my other PPE with patients. I am also hard of hearing and wear hearing aids, so having a mask where the straps go around the head and not the ears is so much better for me. I appreciate you taking the time to do this. Hope you and yours are hanging in there. Be well!
It’s probably just me but I am confused at step #7 and #8, I sewed 3 1/2″ and inserted wire and the part about zig zag the short ends…..what keeps the wire in place? Love this pattern…..sewing away till I get to this step….lol
Carol, so you slip in the wire (pipes) to the casings and you zig zag the short (mask’s two sides) edges of the mask so the fabric won’t frey. And then the just zig zaged side- short edges fold to one side of the mask and that way you make casings for the elastics. After you make those casing there is just the room for the pipes and keeps it in place. I hope i didnt confuse you more and let me know if you have more questions.
Hi,
First off thanks for the info on making the mask. I used unscented dryer sheets in layers (2 folded in half works well) for filters, also found that a Viva Paper towel works well as a filter, make sure you get the one that are similar to shop towel quality. Also, used a Shammy Cloth as padding in between the material for a thicker mask.
Julia,
kleenex kind. Also, i have read lately that you can use an air filter you use for you furnace. You just need to cut the wires to get the filter out and cut it into pieces.
I use felt as a filter. Works great and no thicker than an N95 mask. I have been using this method for a long time because I have BAD allergies to fest cut grass. When my husband is on a wild fire I have to cut the grass. I was having to buy N95 so I wouldn’t get sick from cutting the grass. I tried everything you can think of as a filter and felt works the best.
Thank you for this wonderful step by step tutorial. Much easier for me to follow than a video. Also I love the one over the head (instead of over the ears). Awesome job?
I only have one comment, use any kind of scent isn’t good it’s over powering to smell for long periods of time. I do work in surgery and when I have a case that’s not great smelling I tried to use essential oils and it made my eyes burn to if you use it go light.
The photos show Daniel (who is very cute!) wearing 2 different masks. One is shown over the ears; one around the head. There is a measurement of 24 – 26” for elastic, and another for 2 8” pieces. This is confusing. B
Ann, you can make the mask two ways. using one long elastic and do it over the head or cut two shorter pieces and make it over the ears. Hope than helps.
I think i’m missing something. I have followed steps 1-5, and twisted the pipe cleaners, but I don’t have casings. The 2 fabric pieces are sewn together at the bottom, and at the top for 3 1/4” on each side. That doesn’t produce casings. Also, the top fabric pieces measure 12”. Two 8” pieces of pipe cleaners measure 16”. Do they overlap?
Hello Claudia,
I know, im working on setting up space and doing videas but still not quite there yet. Thats why im doing detailed tutorials with lots of pictures. If you have any questions, i am here to answer.
Yes, those would work too but if you will be washing and drying your mask in very hight temp. the plastic may melt. I wrote in my post that you can use gauge or flower wire instead.
I want to print this pattern for surgical mask and surgical hat. Can’t seem to do that. Our hospital is asking for people to make these for our hospital. Please help
Hello, the link for the pattern is in my library that i think you got in. I just checked and the link for pdf pattern is there for you to print out. Hope you found it!
P.S. that surgical cap pattern is for a child size head.
Love this patter, its so easy.
Can the masks made with pipe cleaners be washed in a machine. Plus can they be dried in a tumble.
Sue, I’m glad you like my face mask tutorial. I have washed and dried my masks several times and the pipe cleaners are fine. You may need to straighten them out but otherwise they worked for me. Also, I have found wires for the nose on amazon, you may want to get those.
Hi – I don’t do much sewing but made the mask after a few mistakes – your tutorial was excellent- thanks so much – saw some elastic for sale but now can’t find it?
Margaret, its great you liked my tutorial. I know, it’s hard to get elastic these days. Stay well
There are so many comments I may have missed the answer to my question. What’s the best way to wash the mask? With the wire in it and the elastic exposed I want to wash it properly so it lasts. Thanks for posting these directions!!
April, I wash my face mask in a washer on hot and normal dry and the wire and elastic is fine.
THANKS so much for sharing. One question – for over the head, how is the long elastic inserted? Can’t seem to figure it out
Carol, same as for over the ears through the side casings. The difference is for over the head you insert one long elastic. Hope that helps.
Could a video be done showing the side casings being made? That part confuses me too much.
Mollie, you need to just fold both sides 3/4″ to one side and stitch. Hope that helps.
Please add me to your library.
Thank you for your creativity and simple explanations
Can this mask be reversible?
Jeena, not the way i made it.
You wouldn’t want it reversible. Public germs would be next to your skin. Your germs would be exposed to the public. Sara RN
Sara, I was thinking once it was washed/disinfected & I had different patterns on each side allowing the person to choose which pattern/side they would like to wear. Especially kids…i. e. stars on one side super hero’s on another Or solid on one side pattern on the other for adults. They could only change sides after it being washed, not while wearing it. I’m assuming that would be ok.
Thank you for this pattern. I have made a similar pattern that you use Paracord with a loop on bottom for neckline and then tie at back of head. I love your elastic around the head better! Now to find elastic in my stash as it is not available in stores.
Thank you Winnie!
Would a coffee filter be advisable?
Marlene, according to CDC rules, you can use coffee filters for your mask.
Hi, I would not use a tissue as a filter it gives no protection! The best thing to use is the blue shop towels. they are ”hydrophobic”, which means they don’t absorb water or virus! Cut them to fit your pocket and use two layers. My son has a masters and works in this field. Google it if you like!
Gaile, Thank you for your advice! Stay well and safe!
How about paper towel into pocket instead of tissue?
That may work, although according to CDC guidelines, cut up coffee filter is ok.
I’m using umbrella fabric as the middle layer, between 100% high quality cotton. A Dr from China recommended umbrellas!
Interesting, Debbie!
Gaile,
Thanks for your comment/suggestion.
I was planning to contact 3M tomorrow to inquire about the components of the “blue shop towels” since I saw an article recommending them as face mask filters due to their good filtering ability, but I can’t imagine that towels used for workshop or car cleaning would also be “pure” enough to be breathing through. Can your son give any info regarding that?
They are certainly cost friendly. Thank you for your further input.
I’m confused by step 8. It says 3’4”. Do you intend it to say 3/4”?
Carol, yes! 3/4″ – I just corrected it. Thank you!
Is it possible to use old jeans for the material since it is a heavy type of material? I have a lot of those and was going to make a quilt but could use it for this. Just if you think it will work. Thank you so much for the pattern and instructions.
Paula, the jeans might be to thick for a mask. I would recommend using 100% cotton fabric.
Thank you so much for this pattern. I am a RN on our hospital’s Covid unit and I now have to wear a cloth mask all the time at work when I’m not wearing my other PPE with patients. I am also hard of hearing and wear hearing aids, so having a mask where the straps go around the head and not the ears is so much better for me. I appreciate you taking the time to do this. Hope you and yours are hanging in there. Be well!
Thank you Nancy for what you do as a medical worker! Stay well and safe!
Is quilting material a necessity?
I have cotton material or an old comforter I can cut up.
Yes Beverly, just make sure it is cotton.
Thank you so much for this tutorial. I looked at a few others but found yours easy to follow!
That’s great! Thank you!
Thank you! I’m going to make some today. I read you could cut up a vacuum bag as a filter.
Yes, vacuum bag filter or cut up air filter.
But just make sure the filter used does NOT contain fiberglass.
It’s probably just me but I am confused at step #7 and #8, I sewed 3 1/2″ and inserted wire and the part about zig zag the short ends…..what keeps the wire in place? Love this pattern…..sewing away till I get to this step….lol
Carol, so you slip in the wire (pipes) to the casings and you zig zag the short (mask’s two sides) edges of the mask so the fabric won’t frey. And then the just zig zaged side- short edges fold to one side of the mask and that way you make casings for the elastics. After you make those casing there is just the room for the pipes and keeps it in place. I hope i didnt confuse you more and let me know if you have more questions.
No you didn’t Thank You….so simple and as usual I was trying to make it difficult.
How is the elastic secured in? Did you fold the ends on the side over the elastic? Can I see a picture?
Sharon. I just made a knot and shifted the elastic that the knot is in the casing. Hope that helps.
Hi,
First off thanks for the info on making the mask. I used unscented dryer sheets in layers (2 folded in half works well) for filters, also found that a Viva Paper towel works well as a filter, make sure you get the one that are similar to shop towel quality. Also, used a Shammy Cloth as padding in between the material for a thicker mask.
Be well!
LF
Elizabeth, thank you for the ideas! Stay well and safe!
I wouldn’t used dryer sheets, even if they are unscented. There are so many toxc chemicals in those. https://draxe.com/health/dryer-sheets/
When you say tissue paper, are you referring to kleenex, or the kind for gifts.
Julia,
kleenex kind. Also, i have read lately that you can use an air filter you use for you furnace. You just need to cut the wires to get the filter out and cut it into pieces.
Thank you for the great instructions, I read them and they are very straightforward and easy.
I have read though, that you really have to read what the filters are made of. (some can contain fiberglass) just a warning.
Hello Jan,
Its great you like my tutorial, it makes me super happy. I know, I am a little confused about what to use as a filter.
I use felt as a filter. Works great and no thicker than an N95 mask. I have been using this method for a long time because I have BAD allergies to fest cut grass. When my husband is on a wild fire I have to cut the grass. I was having to buy N95 so I wouldn’t get sick from cutting the grass. I tried everything you can think of as a filter and felt works the best.
Cathy, thank you for your recommendations.
those have fiberglass in them
I read that using furnace filters is not recommended because if the particles in then, the same with vaccum bags.
Alice, one of my readers suggested to use blue shop towels. You can read in other peoples comments under my blog post.
I have read that furnace filters should NOT be used in masks. They have fiberglass in them.
Thank you for this wonderful step by step tutorial. Much easier for me to follow than a video. Also I love the one over the head (instead of over the ears). Awesome job?
Thank you! Stay well and safe!
Going to make a few today. Thank you for your pattern. I will let you know how it goes. Stay safe and healthy!!!!
Great! Stay well and safe!
I only have one comment, use any kind of scent isn’t good it’s over powering to smell for long periods of time. I do work in surgery and when I have a case that’s not great smelling I tried to use essential oils and it made my eyes burn to if you use it go light.
Hello Tracy,
you need to be careful with essential oils, you might be allergic to some of them and some of them are very strong.
The photos show Daniel (who is very cute!) wearing 2 different masks. One is shown over the ears; one around the head. There is a measurement of 24 – 26” for elastic, and another for 2 8” pieces. This is confusing. B
Ann, you can make the mask two ways. using one long elastic and do it over the head or cut two shorter pieces and make it over the ears. Hope than helps.
I think i’m missing something. I have followed steps 1-5, and twisted the pipe cleaners, but I don’t have casings. The 2 fabric pieces are sewn together at the bottom, and at the top for 3 1/4” on each side. That doesn’t produce casings. Also, the top fabric pieces measure 12”. Two 8” pieces of pipe cleaners measure 16”. Do they overlap?
Ann, in step 2 it shows to make casings on both pieces. you put the pipes to each casing.
cant find the pdf for mask pattern.
Kalay, for the mask there is no PDF pattern just a step by step tutorial on my post, where i wrote the measurements for the mask.
a video would be great for beginners like me, thanks
Hello Claudia,
I know, im working on setting up space and doing videas but still not quite there yet. Thats why im doing detailed tutorials with lots of pictures. If you have any questions, i am here to answer.
Can you tell me if these can be autoclaved with the pipe cleaner?
Hello, I don’t see why not?
100% cotton can be steam sterilised. Not sure about the pipe cleaner. The fibres may melt at 134°C.
Good point! instead pipe cleaner you can use gauge or floral wire.
I would not autoclave using pipe cleaners the fibers might melt.
Yes, I stated that in the post. You can use gauge or flower wire.
Any ideas on other options for the nose wire instead of pipe cleaners?
Hello Natalie, You can use gauge or floral wire, both you can find on amazon. Hope i helped.
I’m going to use those flat twist ties that come with coffee bags!!
Yes, those would work too but if you will be washing and drying your mask in very hight temp. the plastic may melt. I wrote in my post that you can use gauge or flower wire instead.
I used those but I made my pleated masks with a little pocket so it can be removed for washing
Rubber coated Flower wire or wide bread twist ties
I want to print this pattern for surgical mask and surgical hat. Can’t seem to do that. Our hospital is asking for people to make these for our hospital. Please help
Hello, the link for the pattern is in my library that i think you got in. I just checked and the link for pdf pattern is there for you to print out. Hope you found it!
P.S. that surgical cap pattern is for a child size head.
Hello,
Here is tutorial for the SURGICAL MASK and also tutorial and free template for SURGICAL CAP. Thank you for supporting hospitals in need!