How To Make a Face Mask with Filter Pocket + Ties
I just learned how to make face masks last week and if you had asked me whether I would write/shoot a tutorial I would have said HELL, NO. For a couple of weeks, I was resistant to mask making out of sheer exhaustion and since our ski neck warmers were serving the purpose. However, then I couldn’t keep up with laundering our ski neck warmers fast enough so I finally broke down and decided to learn. I tried some of the easier approaches but they felt super clunky on my face. As I reviewed tutorials I kept looking for ways to optimize the process and a bunch of people recently asked me for a tutorial so here I am. I have essentially created a hybrid based on this New York Times mask tutorial and pocket mask tutorial, adding tweaks along the way. By my eighth mask I finally felt like I nailed the approach so I’d like to help you avoid seven masks worth of trial and error!
And since I’m a super visual learner I thought it would be helpful to shoot some quick video. These are not fancy videos; you will see I didn’t even bother cleaning my office! Let’s get started with preparation and then I’ll launch into construction. I have written out quick tips below but I definitely recommend you watch the videos for additional details and explanations.
How to Batch Prepare Fabric for Face Masks
Before we get to the construction I want to talk batch preparation because even if you’re just planning on making a few masks, it’s so much easier to only think about measurements once! This past weekend I prepared fabric for a half dozen masks before sitting down to sew and it just made the whole process so much more efficient. Here’s what I recommend (the video below walks you through the process):
Prepare fabric. Wash fabric and iron it.
Cut stiff paper templates for mask bases. I use 10” x 6” for adults and 7” x 5” for kids. You will need 3 pieces of each per mask.
Cut mask base rectangles. Figure out which direction will give you the most out of your fabric (unless you have a pattern that requires a certain orientation). Tightly fold your fabric around your paper template as many times as you want masks. Slide the paper out and iron the folds shut. Slide your scissors into and cut the folded sides.
Cut ties. You will need four ties per mask. I use 1.25” to 1.5” wide x 15” long for kid size and 18” inches long for adult. If you’re good at eyeballing, great, but otherwise a ruler is about the right width for the ties so you can line up then tightly fold your fabric around the ruler. Slide the ruler out and press the folds flat then slide your scissors and cut the sides.
How to Make a Face Mask with Filter Pocket + Ties
OK, now that you are good on prep, let’s get to the how to. I decided to share individual step-by-step videos below so it’s easy for you to jump to and repeat different sections, but otherwise here is the full video spliced together. **INSTRUCTION EDIT: At 12:10 I describe leaving an opening to turn your mask inside out. You don't need to do this because you can simply turn your mask inside out through the pocket open. So just sew all around the edge! Hooray for things being one step easier and apologies for that brain cramp!
How to Make Face Mask Ties
Homemade ties are definitely more time consuming but they offer the best fit. Plus, none of the other options worked for me; I didn’t have shoelaces, bias tape, or elastic (plus, ties offer a better fit than elastic) and ribbon was too slippery on my Asian hair. Here are the basic steps; watch the video for additional details and explanation.
Cut your ties; you will need four per mask (directions above).
Use an iron to press the ties lengthwise (fabric right side out).
Fold over the short end of one length (this will be the tie end that is showing) about one-quarter of an inch and fold in both lengths of rough edge to meet the pressed seam and pin this end shut. This tucks in the rough edges.
Sew the ties shut starting at the ROUGH unfinished end of the tie; repeat for all ties.
How to Make a Face Mask Filter Pocket
Originally I was making tiny little pockets that needed to be hemmed all around. AWFUL. The approach below uses a little more fabric but is way easier. Here are the basic steps; watch the video for additional details and explanation.
Lay two mask base pieces, pattern sides facing each other. Mark the midpoint on the short sides. Draw a line down the long side leaving a 3-inch gap in the center.
Sew down the marked lines.
Turn the fabric right side out. Smooth seams and topstitch tight along the line on both sides of the seam to reinforce the pocket.
How To Add Ties to a Face Mask
One genius (IMO) thing I figured out when I was creating my hybrid mask approach is that the pocket approach gives you a way to not have to bunch your ties inside your face mask layers as you sew them down. This means less chance of accidentally sewing your ties down where they shouldn’t be sewn! Here are the basic steps; watch the video for additional details and explanation.
Lay your third piece of fabric pattern side down lined up to the pocket double layer.
Place two pins perpendicular to mark the area you should not sew (the hole you need to turn the mask inside out). Also place pins along the corners to remind yourself to stop sewing so you can add your ties! *INSTRUCTION EDIT: At 0:49 I describe leaving an opening to turn your mask inside out. You don't need to do this because you can simply turn your mask inside out through the pocket open. So just sew all around the edge. Hooray for things being one step easier and apologies for that brain cramp!
I like to start sewing at the first barrier pin (marking where not to sew, in order to turn the mask inside out). Sew the short distance from this pin to the seam edge of the next side (about one-quarter inch from edge). With the needle in place, lift the sewing machine foot and turn the corner by rotating your fabric.
Take the raw, unfinished edge of one of your ties and snake it up through the pocket hole so it is now between your pocket double-layer and your third mask layer. Line the tie up flush to the short edge of your mask fabric so it is parallel to the long side of your mask. Sew the seam, taking care to slow down as you go over the tie. As you approach the next corner, stop about one inch from the corner. With the needle down in fabric, lift the foot, snake your second tie up through the pocket hole, line it up as before, and sew it down, stopping about a quarter inch from the end of that side. Turn the corner. Repeat these steps for ties 3 and 4 and sew until you get to the final barrier pin. *If this sounds confusing, definitely watch the video! I walk you through the whole thing!
Flip mask inside out. Pull your ties through to help you. Use a chopstick, paint brush end, or pen to poke out the mask corners. If you don’t mind ironing, this would be a good time to iron. If you hate ironing (like I do) smooth everything as flat as you can by hand.
How To Make Face Mask Pleats: Final Assembly!
WOO HOO! You’re almost there! Here are the basic steps to make the pleats and finish your mask. Watch the video for additional details and explanation.
The front side of the mask (not pocket) is where you’ll do your pinning and sewing. Pin the opening through which you pulled your mask right side out. Put a couple of pins along the other long side as well, pulling the seam tight.
Pin your pleats. On the front (not pocket side) side, make your first pleat midway down the short sides of the mask, aligning with the pocket seam on the reverse. Repeat on the other short side. Add one pleat above and below each short side for a total of 3 pleats on each side.
Sew all the way around the four sides, with about a quarter inch seam, making sure to keep your ties clear. Take care and go slow as you go over the pleats and tie fastenings because OMG so many layers. This is not the time to break your machine! (In fact, after my sewing machine started making a horrible hammering noise when I sewed, I replaced the needle and everything was better!)
After you sew around the four sides, REPEAT and sew all the way around again, moving in a ¼ inch (or less on the child’s mask) to secure your pleats with a double seam.
Insert filter! We are using coffee filters and shop towel filters.
I hope this tutorial is helpful to you! Let me know in the comments if you have questions!
How to make a face mask with filter pocket + ties, including step-by-step videos