DFW COVID PPE Sewing Relief Group Mask Sewing Guide Vs 1.

Website: http://dfwsewingrelief.org/ Email: info@dfwsewingrelief.org

Facebook: @DFW COVID PPE Sewing Relief Group

We have worked hard to research the various mask patterns and talk with healthcare providers in determining
this mask pattern is best for the needs of our healthcare community at this point in time.

We will continue to evaluate the needs and uses of our masks and may need to make changes to this pattern
based on feedback from our users. We will also update this pattern to improve the clarity of the instructions.

There will be a video tutorial that matches this process coming shortly. Watch our FB page for updates.

Supplies:
• 100% cotton fabric, preferably a dense weave like is found in quilt fabric (do not use polyester, cotton-
poly blend, knits or any type of synthetic fabric.
• Elastic – 1/8” or ¼”, or anything that can be used as ties, as long as the ends can be finished to not fray
• Soft wire such as chenille stems, florist wire, twist ties (twist ties may need to be “doubled” in a twisted
manner to create a single tie)
• Sewing machine and general sewing supplies

Let’s Get Started!

• Cut 2 - 9” x 7” pieces from 100% cotton fabric

Note: it is preferred that 2 different fabrics be used so as to tell front and back
• Cut 2 – 2” x 6” pieces from 100% cotton fabric (this can be the same as one of the mask fabrics)
• Cut 2 – 6” strips of elastic
Note: if using fabric or ribbon ties, cut 4 – 18” ties
• 1 – 6” piece of soft wire (chenille stem, florist wire, twist tie)

Cut to 6”
2” x 6”

6” 9” x 7”
1) Sew 9” x 7” fabric right sides together using a ¼” seam.
I am using dark thread to help show the stitches, but you can use
thread that blends with the fabric.

2) Turn right side out and press, taking care to make sure the seams
are smooth.

3) Cut 6” length of soft wire and turn ends in approx. ½”

In the first picture, see how the ends are bent such that
then lay flat against the stem as in picture 2

4) Slide the soft wire into the top of one sewn side
(9” side) of the mask and push it snug against the
seam.

Center the soft wire and secure in place

with pins
5) Stitch close against the soft wire to hold it in place.
Sew the ends of the pocket to secure the soft wire in place.
Stitching does not have to be exactly next to the soft wire, but we are trying
to create a small pocket to keep the soft wire from re-positioning within the
mask.

6) Pleat the fabric. Turn the mask sideways and make 3 narrow Front of mask with pleats
pleats in the mask (both layers of fabric).
Pleats should be approx. 1” –Adjust to make pleats approx.
equal in size. Pin pleats on both sides of mask.

Side of mask with pleats

7) Sew along the short side of the mask. Repeat on the other side.
Be sure the catch all layers of the pleat when sewing.
 Here is what the front of the mask should look like at this point.

8) Pin 6” section of elastic on the front side of the mask, approx.

½” from each edge.

9) Sew approx. ¼”from the raw edge, making sure to backstitch

across the elastic to secure.

Here is what the back should look like at this point.

Top of mask
10) Take each 2” x 6” piece of fabric, fold in half along the long side, press.

11) Center and pin the folded 2” x 6” strip along the short
end of the mask, matching raw edges, on the front side
of the mask. You will have approx. 1” overhang on each
side.

12) Sew ¼” from the raw edge, making sure to sew the entire
edge of the mask. You will have approx

13) Fold the extra fabric around the mask edge and pin to
secure.
 14) Sew ¼” from the edge from the front side of the
mask, making sure to capture the flaps on the
underneath side of the mask.

Be sure to keep the elastic free from the area

being sewn.

Front of mask

Back of mask

15) Flip the fabric cuff up, and then fold the
front of the cuff over to the back of the
mask, covering the raw edges of the cuff.
Pin to secure in place, making sure to tuck
the raw edge ends completely under the
cuff.

Back of Mask Front of Mask

16) Sew close to the edge of the cuff, backstitching on each Back of Mask
edge.
Repeat for other side.

Ta Da! You have finished a mask! Congratulations and THANK YOU!

Video tutorial of this process will be posted to the DFW COVID PPE Sewing Relief Group FB page soon.
You may also use ties instead of elastic, creating 4 – 18” ties and placing the ties inward toward the mask
center approx. ½” from each corner, just as we did with the elastic.

For a different process for the same mask pattern that also provides ideas for different types of ties, go to:
https://www.youtube.com/watch?v=L55CNVm2FXw&feature=youtu.be