Updated: Feb 16, 2021
Over these last few months I have uploaded a number of tutorials for reusable fabric masks. After many days and weeks of wearing masks for hours on end I find this pattern to be the most comfortable. I have made myself 10.
I wash them together with regular washing at 40 - 60 degrees after every use which is more or less once a day.
This is the basic pattern and can be adjusted to face width and height.
Start by drawing a rectangle of 16 x 14 cm. Draw a line at the centre height. At the top mark 14 cm and at the bottom 12 cm. On the right side from the center point mark 4 cm up and down and from there 3 cm to both corners.
Draw a line from the 14 cm mark to the point between the 3 and 4 cm mark. Do the same on the bottom from the 12 cm mark to the point between the 3 and 4 cm .
This pattern is for one side of the mask and has to be doubled.
I mark a curved line (the blue pen mark) which is my actual mask pattern. I draw a large curve over the nose and mouth area from the 14 cm to the end of the 16 cm and curving down towards the 12 cm. I also curve in under the eye area which is from the 14 cm point to the mid 3 - 4 cm point.
The newly drafted pattern.
Cut out 2 pieces from a piece of upcycled sheet to create a draft pattern. Stitch along the curved nose and mouth area.
Try the draft mask on and make adjustments. The curve over the nose and mouth might be too deep, it might not be deep enough and the length of the mask from nose to ear might be too long or too short. Keep in mind that you are going to fold over 2 cm at both ear areas to create a tunnel for the elastic or t shirt cording to pass through.
This is your draft mask. Once you have adjusted it you can now cut out the fabrics for the actual mask. If you are going to sew a 2 layered mask you will need to cut 4 pieces from this pattern in 2 different colors. 2 for outside and 2 for inside. If you are making a pocket for a filter you will need an additional 2 pieces which are exactly the same size but shorter towards the ear are by about 4 cm on each side. You will also need a strip of t shirt cording made from t shirt hems. You can see a tutorial here https://www.priganart.com/post/a-visual-tutorial-on-how-to-turn-the-t-shirt-tubes-inside-out of how to make it, or a piece of elastic. I find the t shirt cording to be more comfortable.
This purple mask is made out of 2 layers so I needed to cut 4 pieces, 2 of each color.
Stitch the over nose and mouth area of each pair of fabric.
Iron them flat.
Turn them inside out and iron the curves making sure that they lie flat.
Open them out and lay them down face to face one on top of the other making sure that the curved under eye part is on top on both of the colors as the angle of the mask is different on top and bottom.
If you want a pocket for a filter. Sew the 2 shorter pieces together over the nose and mouth curve and hem the 2 side pieces. Lay this piece down on the color that will be on the inside of the mask and stitch it down on the top and the bottom making sure that the sides are an open pocket. Now take this doubled piece and lay it face down on the right side of the outer piece.
Stitch all around both pieces leaving an open window on the top side to enable us to turn the mask inside out.
Both pieces have been stitched together with the right sides facing inwards.
Now turn the mask inside out via the window that you left open on the top of the mask.
Press the pieces flat down.
Push the corners out with the point of a knitting needle and iron the edges of the mask.
Top stitch around the edge of the entire mask closing the window at the same time. Fold the sides down by 2 cm from each edge and stitch in place. This creates a "tunnel" where the t shirt cord lies to tie the mask.
The finished mask before threading the t shirt cord through the 2 sides.
The completed mask with t shirt cord threaded through both sides.
This is the agle of the finished folded mask.
Side view. I draw a deep curve over the nose as I find it more comfortable to breathe in the mask this way.
Experiment with draft fabrics till you get a pattern which is comfortable and then make a few masks so that you have enough to be able to wash and interchange them.