During a Zoom meeting recently, the light and angle were just right and I could see droplets spraying out of a meeting participant’s mouth when he was simply talking. It made me realize how critical it is to have a mouth covering to stop the spray from your own mouth and also to block others’ droplet shower from landing on your face. 

The mask patterns and tutorials I found online were fabric copies of regular medical masks, with elastic around the ears. Soon, elastic became impossible to find, and reports began to come in that people’s ears were sore from the elastic loops chafing their skin–I then began to see patterns for little pads to put on the elastic to relieve the irritation. These first fabric masks were intended to help battle the severe shortage of personal protective equipment (thanks to the pandemic, we all know what PPE means!) in hospitals.

The face coverings we have been asked to wear by our local health departments are a little different–they are intended to be fabric barriers primarily to limit the amount of droplets flying when we are out and about, still using social distancing but forced to come closer than 6 feet in some instances. We are not in constant, close contact with infected people like health care providers in a hospital setting; we are taking precautions for our community. 

My aim was to make a mouth and nose covering that is relatively comfortable and doesn’t make breathing too hot or restricted. It needs to be a new-normal accessory that I don’t mind wearing and is washable and durable. Combining ideas from mask patterns I found on the internet, I made this version. It uses a single cloth tie, looped around the neck, to gather three layers of cotton fabric into “pleats” that are adjustable and fit closely around the side of the face while leaving a little ease around the mouth and nose.

Since they don’t need to be medical-grade or incorporate filters to comply with the local requirements, I did not put a filter pocket in my masks. Any of the details can be easily changed to suit your preferences, like looping elastic through the casings instead of cloth ties, or leaving an opening for a coffee filter or other non-woven liner. 

My Mask: Step One

Cut one 8” x 11” piece for the mask front, and two pieces 8” x 7.5” for the lining, one of plain muslin if desired.

This is quilting cotton and plain muslin. I am having fun mixing patterns to make unique masks.

Step Two

Place the front and lining pieces right sides together, centering the narrower lining pieces on the front piece, and sew ½ inch seam along top and bottom. Press seams flat, turn and press. 

Getting back into sewing after a long slump, I felt like a newbie. At least twice I sewed wrong sides together and had to find my trusty seam ripper.

Step Three

Press a ½ inch fold into short ends of the mask where there is only a single layer of fabric, then fold again to cover the edge of the lining and create a casing for the tie (or elastic ear loops if you choose). Repeat on the other side.

My high school sewing teacher wouldn’t be pleased, but no, I don’t use pins for this.

Step Four

Sew long edges on top and bottom of the mask, keeping the presser foot even with the edge, catching the ironed-in folds. Turn mask and stitch along edge of casing to close it.

Step Five

Make a tie by ripping a strip from the width of your fabric (44-45 inches). Make a little snip 1½ inches from the edge of the fabric and tear it all the way (you may need to tear a straight edge first if your fabric isn’t cut straight).

Lay the strip flat on an ironing board, right side down. Hold one end firmly, and then gently pull the fabric, holding it approximately 8 inches from the other side. (I’m right handed, so I hold with my right and pull with my left). Both edges will curl toward the center. Use your fingers to make edges meet in the middle and press. Pull and press for the length of the strip. Then, fold the strip in half again and sew the length of it down the middle. 

This is the fun part! Rip from selvage edge to selvage edge.
This is my real ironing board cover. I’m not proud.

Note: This is my shortcut method for making bias tape. It’s not actually on the bias, but it seems to be just as stretchy and works fine. By pulling and ironing you get a nice tape without the extreme frustration and burnt fingers of folding both sides to the middle and pressing. You can also buy bias tape pre-folded, but that seems to be hard to find now too. 

Attach a safety pin to one end, feed the tie up through one casing and then down through the other side. Knot both ends. 

If using elastic for ear loops, cut two 10 inch pieces of ¼ or ½ inch elastic. Feed 1 piece through each casing and sew ends together, back stitching several times to make sure it holds. 

The finished mask!

To wear, put the loop over your head with the outside of the mask against you, lining facing out. Pull the mask up over your mouth and nose, tightening the tie on both sides evenly until it’s snug against the back of your neck and sides of your face. Tie behind your head. Adjust the gathers around your nose and mouth so it’s comfortable and hopefully doesn’t steam up your glasses too much.