The DIY Face Mask Tutorial You'll Want for Optimal Protection

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If you find yourself reading this article, then chances are you are looking for a DIY face mask tutorial. With endless tutorials currently to be found, you may be wondering what makes this one different and why you’ll want it for optimal protection.

Unlike other face mask tutorials, this one will help provide you with optimal protection utilizing CDC recommended materials and protective layers. **Disclaimer: I am not a physician, nor an epidemiologist. Instead, I am a mom who put in endless time researching correct face mask styles and materials in order to improve my family’s safety. Here is what I have learned.

CDC Guidelines

According to the CDC, proper protective face masks should include the following (taken directly from the CDC):

fit snugly but comfortably against the side of the face
be secured with ties or ear loops
include multiple layers of fabric
allow for breathing without restriction
be able to be laundered and machine dried without damage or change to shape

While multiple face mask tutorials on the Internet address the majority of the above elements, MANY fail to include multiple layers of fabric. That is where my tutorial differs. Simply utilizing one layer of fabric will not provide enough protection, instead consider using the following materials.

Correct Fabric Materials

My research suggests that the optimal fabric to use when making your own face masks is 100% cotton. Ideally the cotton would be medium or heavyweight. I found all my fabric here and had it delivered directly to my door. This is where you have options.

If selecting a heavyweight 100% cotton, you are far more protected with a single layer of fabric than with a lightweight 100% cotton piece. However, for optimal protection, it is still recommended to add an additional layer of lighter cotton behind.
Not wanting to use a heavyweight 100% cotton (or don’t have access to it)? That is okay. Simply double up on the 100% cotton that you do have. This is where two layers of fabric are all the more important and add a filter pocket.
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The Test

It is said that the makeshift test to see if your mask is protective enough is to hold it up to light. If you can see light coming through your mask then the layers are not thick or protective enough.

Filter Pocket?

By doubling up on fabric you can create a filter pocket on the back of your mask. This is the exact technique I show you in this face mask tutorial. This filter pocket allows you to slide in a medical grade face mask or a filter piece of material (i.e. stacked paper towel, piece of 100% cotton fabric, etc.). By having this filter pocket you are able to use the same medical grade mask again and again inside the reusable mask without it being exposed directly to the air around you.

Caring For Your Mask

The beauty of these masks is that they are reusable. After each use it is recommended that you throw your face mask into a sanitization cycle in your washing machine. I recommend then hang drying so that the mask wouldn’t shrink, lose shape or form. Remove filter within the pocket prior to washing.

Tutorial

Time for the tutorial! While I am not a professional seamstress, I will show the basic steps to create your own face mask with a filter pocket. Need to freshen up on your sewing skills? Find out how I taught myself to sew (and you can too!) here. I created three different mask patterns for my family and will show all below.

These styles include:

Black masks– 100% cotton heavyweight outer layer. 100% cotton lightweight inner layer with filter pocket available if desired (not as necessary with the heavyweight outer layer).
Grey masks– 100% cotton lightweight outer layer and inner layer with filter pocket. It is recommended to use a filter within this mask due to lighter weight material.
Frozen (kids) masks– 100% cotton lightweight outer layer and inner layer with filter pocket. It is recommended to use a filter within this mask due to lighter weight material. These masks were created for my children.

Face Mask Tutorial for Adults:

Cut a rectangular piece of fabric to represent the front (outer layer) of your mask. This piece should measure: 9.5 in. x 7.5 in. (For kids mask this piece should measure: 7 in. x 5 in.). If making a large number of masks, I recommend making patterns as shown below and using them to trace fabric pieces.
Cut TWO rectangular pieces of fabric to create a pocket for the back (inner layer) of your mask. Each piece should measure: 7 in. x 5 in. (For kids mask this piece should measure: 5 in. x 4.5 in.)
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Flip each one of the inner layer fabric pieces to the back and fold up the long (7 in.) side 1/2 in. then press flat with an iron.
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Sew the pressed flap down.
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With the outer layer right side up, place the two inner layers (upside down) on top. Have the outer (non-sewn flapped) edges along the outer edge of the front outer layer. Pin both inner flaps down and sew along both edges. Keep approximately 1 in. of outer layer material visible on both sides.

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Open sewn inner flaps and turn entire piece over so that the right side of the outer layer is face down. Fold back both inner pieces so the inner layer flaps are right side up and press/iron down.

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Flip mask back with the front/outer layer showing and inner layers folded behind. Now begin creating pleats on the front of the mask.
Begin with the middle and synch up to create your first pleat, pin at the sides.
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Move to the top pleat and bottom pleat, pinning at the sides and creating a total of 3 pleats.
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Flip over mask and sew along edges of inner fabric so that the pleats are secured in place.
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Now fold over outer edges of fabric twice and sew onto inside of mask. Use elastic, fabric ties, etc. to stitch to top and bottom of both sides. For womens masks, I cut elastic per side to equal 6.25 in. For mens masks, I cut elastic per side to equal 7.75 in. For kids masks, I cut elastic per side to equal 6.25 in.
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Cut filter pockets to fit inside (if you don’t have a medical grade mask to slip inside). I chose to make these out of 100% heavyweight cotton and cut a 4.75 x 3.25 piece for adults and 4 in. x 2.75 in for kids.
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The finished product!
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