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

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Website: http://dfwsewingrelief.org/ Email: info@dfwsewingrelief.org
Facebook: @DFW COVID PPE Sewing Relief Group

Sewing / Pattern Questions: dfwsewingrelief@urbanspools.com

Sewing machine purchase / repair / troubleshooting:
dfwsewingrelief@mrsewingmachine.com
Many thanks to Urban Spools, our sewing support partner!

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.
NOTE: DO NOT use polyester, cotton-poly blend, knits or any type of synthetic fabric.
• Fabric Ties –fabric ties on each corner: 2 – 20” ties (top of mask) 2 – 16” ties (bottom of mask)
• Interfacing (optional) – lightweight interfacing, fusible or non-fusible
• Pipe cleaner: 1 – 6” chenille pipe cleaner.
Craft wire, florist wire, or twist ties can also be used.
• Sewing machine and general sewing supplies

Mask Kit includes supplies to make 36 fabric masks.

72 – 7”x 9” fabric in 2 different colors / patterns (precut)—Use one of each color fabric for 1 mask.
72 – 2”x 6” fabric (precut) for side tabs—Use 2 / masks, one for each side of mask
36 – ½” x 16” fabric strips—Use 2 / mask for lower edge of the mask (ties around the neck)
36 – ½” x 20” fabric strips—Use 2 / mask for upper edge of the mask (ties around the head)
18 – 12” chenille pipe cleaners—Use 1 – 6” chenille pipe cleaner for each mask
(chenille pipe cleaners may already be cut into 36 – 6” sections)
REMEMBER:
• Fabric – 100% Cotton: Please ONLY use 100% cotton fabric for the masks. If you are not completely sure
your fabric is 100% cotton, please be on the watch for an email announcing our mask kits which will all have
only 100% cotton fabric.
• Interfacing: interfacing may be added to provide more protection to the mask than fabric alone, but is not
included in mask kit.
• Nose piece wire: Kit includes 18 chenille pipe cleaners. Please cut in half to create 36 – 6” sections. Craft wire
(16-20G) can also be used if making masks for personal use.
• Video link: The video link at the end of these instructions provides ideas for making ties as an alternative to
elastic, as well as using a serger or wide, close zigzag for the seams. Please use everything else as outlined in
the pattern below so we can have masks that are as uniform as possible.
Let’s Get Started!

1) Organize supplies
For 1 mask you will need: 2 - 2”x 6”
2 – 9” x 7” fabric rectangles (1 of each color) fabric
2 – 2” x 6” fabric rectangles
1 – 6” chenille pipe cleaner
2 – 16” fabric ties
2 – 20” fabric ties
2 - 9” x 7” fabric
The fabric ties will be attached in groups of 6 ties. (1 of each color) 1 - 6” chenille
You will need to snip the ends where the ties are pipe cleaner
connected to separate the ties.

2 - 16” fabric ties

2 - 20” fabric ties
2) Create face section of mask
Sew the 2 - 9” x 7” rectangles right sides
together using a ¼” seam on each short side (7”).
Use 1 of each fabric pattern.
Repeat for the other 7” side.
 Turn right side out and press.

3) Creating pocket for nose piece.

Top stitch ½” from one sewn edge. This will become the top of the mask.
Top stitch ¼” from the other sewn edge. This will become the bottom of the mask.
Topstitch ½” from top sewn edge Topstitch ¼” from bottom sewn edge
Top

¼”

½”

Front Back

Bottom
4) Add chenille pipe cleaner to create nose piece.
Bend each end of the chenille pipe cleaner approx ½”.
Pipe cleaner should be approx. 5” long after bending both ends in.
This prevents the pipe cleaner from poking through the fabric.

Use fingers to position pipe cleaner in the center of the mask, with
approx. 1” between the end of each pipe cleaner and the edge of
the mask.

5) Adding pleats to mask.

Pleat the fabric. Starting at the bottom (not the edge with the pipe
cleaner), make 3 narrow pleats in the mask, with pleat folds facing
“down” from top of mask (with wire) to bottom of mask.

You will be pleating both layers of fabric—front and back

Pleats should start approx. 1-1 ½” from bottom edge with each pleat
being approx. 1/2“wide.
Pin pleats on both sides to hold in place.
 Side of mask with pleats

Sew along the short side of the mask. Repeat on the other side.
Be sure the catch all layers of the pleat when sewing.

Wire is top of mask

Front of mask –pleats face down
Back of mask—pleats face up

6) Attach ties.
Some ties in the kit will have straight edges
and some will have wavy edges.
If the ties are straight, you will need to stay stitch approx. 1/8” from edge, or as close as
you can without running off the edge. This will provide stability to the tie and minimize
fraying.

You can also fold the strip in half and sew a straight seam approx. 1/8” from raw edge.
You can see an example of this tie in the picture below.

Clip or pin the 2 – 20” ties approx. 1” below the top

edge of the mask and 2 – 16” ties approx. 1” from the bottom TOP
edge.

Place the ties right side together with the mask front—so that the
wrong side of the tie is facing up.

Make sure you have the 20” ties on the TOP of the mask and the
16” ties on the BOTTOM of the mask.
Make sure the ties are positioned toward the center of the mask
and be sure to keep the ties free from stitching.

BOTTOM
Sew approx. ¼” from the raw edge.

Snip the ends of the ties at a 45

degree angle (approx.) to minimize
fraying.
Add the angle to the end of all ties,
regardless of the type you are using.
7) Finishing the Edges of Mask:
Fold the 2 - 2” x 6” pieces of fabric in half along the long side
and press.

On the front side of the mask, center and pin the folded FRONT BACK
2” x 6” strip along the edges of the mask, matching raw
edges. There will be approx. ½” to 1” wrapped around
to the back of the mask.

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.

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.

The ties should now be extending away from the side of

the mask.

Flip cuff up Fold cuff completely over to

the Front of mask
Ties should be extending
away from the mask
Sew close to the edge of the cuff, backstitching on each edge to secure.
Repeat for other side.

Bravo! You have finished a mask! Congratulations and THANK YOU!

REMEMBER: Please use ONLY this pattern above to make masks for DFW Sewing Relief.

QUESTIONS???
Our friends at Urban Spools are available to answer all pattern and sewing questions
dfwsewingrelief@urbanspools.com

Free sewing machine diagnostics and support for all sewists volunteering with DFW
Sewing Relief can be sent to the expert staff at Mr. Sewing Machine
dfwsewingrelief@mrsewingmachine.com