I’ve tried several patterns for face masks over the past few months, but the one I wrote about in April continues to be a winner at our house.
Here’s the YouTube tutorial by Keiko Olsson again, and a rough draft of the pattern that I sketched from her instructions…
Today I figured out that I could make the mask from a t-shirt! By ironing interfacing onto the lining piece, I ended up with a three-layered mask, as currently recommended.
I started with an old tee that someone donated on swap day…
I cut the pattern pieces from the front and back at the same time…
Iron-on interfacing was applied to the wrong side of the lining…
I then followed the tutorial pretty closely up to the sewing of the casing…
Instead of turning the casing over twice, I just folded it over once and stitched it down. There were two reasons for doing this – firstly, knit fabrics don’t fray, so there was no need to fold under the raw edge. Secondly, I needed a slightly wider casing to fit ties rather than elastic…
After stitching down the pleats, I added a small diagonal seam in the middle of the bottom of the mask, sewing with right side folded in half on itself. You can see it at the top of the photo below. This contours the mask just a little so that it tucks in under the chin…
To make the ties, first cut the hem off the t-shirt, then cut a 4cm (1½”) strip straight across the body. Turn it inside out and cut off the seams…
Now give each strip a good tug and the edges will curl inwards to form a long cord…
With a large wool needle, feed each tie through one of the side casings. This bit can be a bit fiddly and you might need to improvise…
We find the ties work far better than elastic (which we all found very hard on our ears), and allow the mask to be worn in a number of ways. My personal preference is to tie one set high on the top of my head and the other behind my neck. Additionally, hat elastic is almost impossible to buy at the moment, so being able to make ties on the spot is a bonus.
My stitching was a bit wonky but the knit fabric is very forgiving…
Lastly, don’t throw away your scraps! Cut them into usable pieces, then stash them in the laundry for polishing shoes or dusting…
These upcycled t-shirt masks tick all the sustainability boxes, but they are in no way surgical grade or guaranteed to protect against COVID19. They might, however, help prevent the wearer from spreading the disease unknowingly. According to the information provided by the Department of Health in Victoria, face masks should ideally be made with a water resistant external layer. We’ve been experimenting with outerwear scraps with some success, but have found masks made with completely waterproof fabric to be impossible to breathe through.
Have you been sewing face masks? Please feel free to list any patterns you’ve found useful in the comments below for discussion and comparison. ♥
Fig Jam and Lime Cordial 
I joined a group in Toronto in April, we were sewing masks and scrub caps for front line workers when supplies were non-existent. There were about 200 sewists and we made just over 26,000 masks! It was awesome to be a part of something that made a difference. In addition to the masks and scrub caps I sewed for the volunteer group, I also sewed masks for family and friends! I prefer the cup-style pattern with elastic that goes around your head instead of ears. I used this pattern: https://www.craftpassion.com/wp-content/uploads/2013/08/men-face-mask-template-rev3.pdf
With the following alts:
1. Add 1 cm to the bottom of the mask of the exterior fabric.
2. Pin top elastic to top corners.
3. With right-sides of exterior fabric and lining together, sew around the side, top and side leaving the bottom open.
4. Add nose wire by zigzagging a wire to the seam allowance of the exterior fabric. I used heavy duty twist ties.
5. Turn mask right-side out and press, top stitch around sides and top (the corner elastic will help pull out the corner)
6. Prepare bottom casing for lower neck elastic. Thread the elastic through and tie off.
It’s summer over here now and the masks are extremely uncomfortable in the heat and humidity of Toronto, I usually add a single layer of paper towel into my mask to help wick the sweat away from my face, if I need to wear it a long time (at the hairdresser).
We like the fit of the Jesse Killion mask. It has a space in front of the nose and mouth that makes it easier to breathe. I had to modify it slightly to fit for larger ears. We also like upclycled t-shirt ties. https://media.rainpos.com/220/jessemask.pdf
A friend has added a clear plastic shield along with the mask. She covered the manufacturers label with “Have Mask, Will Travel” in large printing, with small printing below “If you can read this you are too close.”
I call this my origami mask due to the clever folding. There are lots of different versions on you tube, I just finished sewing one tonight in broder anglaise with cotton lining, with top stitching on the horizontal folds to give it structure. I have toyed with the idea of a t shirt – just can’t decide which one to cut up as op shopping for one here in Melbourne at the moment is a little more complicated than usual!
I’ve used the dhurata Davies free pattern fits nice and snug and lined with a lovely soft worn out shirt
Wow! I’m really impressed with your latest mask. It looks so professionally made and actually a desirable item.
I can’t wear a mask because it induces panic in me but today I have received face shields (a plastic visor which straps on at the forehead and goes down below the chin). They don’t look as snazzy and aren’t as sustainable (though reusable) but at least mean I can get out!
A fine tutorial
you are so darn clever celia. wish i had your talent:)
I make an exception for you though xx here I am and I will forward this to my mask maker who is constantly tweaking patterns !