Mask with adjustable nose piece and filter pocket

Difficulty level Intermediate
Time to Complete Weekend
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how to sew a mask

Materials

  • Exterior fabric 8” x 7.5”
  • Lining fabric 8” x 7.5”
  • Binding fabric 2.5” x 10”
  • 6mm elastic – 12” x 2 pieces, Pipe cleaner or twist tie – approx. 6”
  • Sewing machine and thread to match
  • Scissors, Wonder clips, Fabric marker or pencil

Fabric considerations

  • Fabric must be pre-washed in warm or hot water as we expect the masks to be laundered many times over
  • Exterior fabric is recommended to be mid-weight polyester, quilting cotton or jersey
  • Lining fabric should be a lightweight cotton or cotton/poly blend as it is close to the skin
  • Having a different fabric for exterior and lining allows the user to quickly identify the front of the mask
  • Consider upcycling fabrics for this project: for example, bed sheets work well for lining fabric

Method

Picture: Mask with adjustable nose piece and filter pocket

1. Preparations

Prepare binding strip by folding lengthwise wrong sides together and press. Open strips and press long edges towards the centre and press in place. Fold in half on original press mark, and press. Put aside.

Picture: Mask with adjustable nose piece and filter pocket

2. Step

Zigzag or serge 7.5” edges of exterior fabric and lining fabric. Place lining fabric and exterior fabric right sides together, mark 1.5” from each side on the top edge to mark an opening. Sew from each edge to the mark.

Picture: Mask with adjustable nose piece and filter pocket

3. Step


Press seam open. Top stitch around the opening.  Place fabrics right side together once more. Sew the bottom edge to create a tube. Turn right side out.

Picture: Mask with adjustable nose piece and filter pocket

4. Step


Manipulate the mask so ½” of lining fabric shows above the opening, press. Sew around the mask with a narrow 1/8” seam. Lift the lining fabric at top of mask to insert twist tie or pipe cleaner. Sew on existing seam line to close.

Picture: Mask with adjustable nose piece and filter pocket

5. Step


Fold mask to create 3 horizontal pleats. Secure with clips and press. Sew along edges with 1/8” seam to secure pleats. (The aim is to make the mask height 3.5” to 4”)

Picture: Mask with adjustable nose piece and filter pocket

6. Step


For each side of mask, cut the binding strip 1” longer than the height of the mask. Open the strip and place right side of strip against lining fabric, aligning the raw edges, and folding the excess fabric strip to the front of the mask.

Picture: Mask with adjustable nose piece and filter pocket

7. Step

Flip mask over and sew on the binding fold closest to the edge of the mask.

Picture: Mask with adjustable nose piece and filter pocket

8. Step

Pull the binding strip away from the mask. Fold the edges of the binding strip in towards the mask, and refold the binding towards the mask, covering all the raw edges.
 

9. Step

Slip the elastic into the folded binding. Clip in place and stitch close to the folded edge, avoid sewing the elastic. Repeat for other side of mask.
 

10. Step

Knot or stitch the elastic into a loop on each side of mask. Pull on the elastic to allow it to slip into the binding. Your mask is ready to wear.

Material substitutions
Elastic:  Use any elastic up to about 8 mm wide. If you do not have elastic, you can cut jersey (knit) material into ¾” strips and use that as an elastic replacement. Alternatively, you could make the binding strips much longer and use them as ties.
 
Pipe cleaner:  Any malleable aluminum will work to replace the pipe cleaner or twist ties. You could cut 1” x 3” pieces of disposable aluminum pie plates or baking dishes. Fold the long cut edges into the middle just like making binding; this will avoid any sharp edges. Fold the short edges in as well.

Thanks for joining us on this project.


Look for a video showing these steps on our YouTube Channel: BERNINA Canada.