SewLibra:
For the pattern use sturdy copy paper, cardboard or similar. Make a rectangle of 7 1/2" x 9" for the main fabric and lining. The binding pattern for the sides of the mask is 1 3/4" x 4 1/2". This is an adult size.
SewLibra:
Our newspaper had a template for marking the pleats. I changed the height a bit to fit the mask at the point where the template is needed. By scant 3/8" I mean almost but not quite 3/8". You can make it 3/8", this is just how the newspaper had it.
SewLibra:
Other than 100% tightly woven cotton for the main fabric and lining, you need 1/4" or 3/16" elastic for the ear loops, 6" pipe cleaners for the nose/upper cheek wire, and optional coffee filters to place in the filter pocket for extra protection.
SewLibra:
I'm starting with 100% batik for the main fabric (batik is recommended) before going on to quilting cotton which is ok too. My lining is tightly woven Japanese cotton lawn. I'm using a rotary cutter and will cut several at a time.
SewLibra:
Using cone thread will save my small spools of colored thread. Put a cone on a thread stand or in a coffee cup and place it behind the machine. For my Brother I pulled it through under the lid and could sew with the lid down. No tension problems.
SewLibra:
Since I plan to make lots of masks, I decided to switch to my Bernina 1008. No bells or whistles, but more power, fast, and sails through multiple layers. I used the thread stand with cone, and am using my serger on only one edge of the fabrics.
SewLibra:
The inside is nice and neat. The Japanese cotton lawn is perfect for the lining and the bindings cover the raw edges of the sides.
SewLibra:
Showing the pocket for the optional extra filter. It opens up from the top under the nose wire and there is plenty of room to access it. I wore just one layer of coffee filter and took it out before I even got out of the car. I found it hard to breathe!
SewLibra:
Due to the pleats the mask opens up and will cover the chin if desired. The binding at the sides help it from gaping out near the ears. The upper wire shapes to the nose and cheekbones.
SewLibra:
Fully opened the mask adjusts to fit many people. Completely machine washable and dryable. I'm not sure how the pipe cleaners will hold up but many people are using them. They are sturdier than twist ties for sure.
SewLibra:
For mass production of masks, cut out as many as you can at one time and do the same step to each mask before going to the next step. This saves time so you are not up and down all the time for pressing and other details.
SewLibra:
Serge (or make a tiny folded hem) at the long 9" edge of both main fabric and lining. No need to finish off the serger threads or use Fray Check, just cut them off even with the edge of the fabric. These edges will be sewn over the serging.
SewLibra:
Keep one serger chain running for all the pieces you have cut. Once you reach the end of a piece and it has passed by the back of the foot, start another piece. When done just cut the chain between pieces!
SewLibra:
Fold down the serged edged of the main fabric 1/2" to the inside. Fold down the serged lining edge 1" to the inside. Press both.
SewLibra:
As long as you have the steam iron on to press down the main fabric and lining, it will save time to go ahead and press your bindings right sides out, lengthwise. You'll thank yourself later. :)
SewLibra:
Stitch on the serged stitches or at the folded edge if you made a narrow hem. You are creating the channel for the nose wire on the main fabric, and keeping the hem down on the lining.
SewLibra:
You can chain together this step on a sewing machine just as you did the serger. Instead of letting the fabric pass to the back of the foot, just make a few "blank" stitches and start on the new piece. This really saves time when making multiple masks.
SewLibra:
I put 20 yds of elastic in a small plastic container with the lid loose on one side. I cut the size needed and used a black Sharpie pen on each end for visibility. That's my guide to cut all the elastic pieces at one time.
SewLibra:
Use pliers to firmly bend the tip of each end of a 6" pipe cleaner. Make it tight! This is to keep it from poking through after laundering and possibly making a hole or hurting someone. I do this in one sitting for all wires needed.
SewLibra:
Place the pipe cleaner at the center top of the lining and make a small dot 1/8" from each end and 1/8" to 1/4" down from the fold. With a 6" pipe cleaner your marks should be 1 1/2" from each raw edge. The dot will be your pivot point.
SewLibra:
I found only one Wonder Clip (or pin) was sufficient for holding the lining on for using the chain method of sewing. Right sides together sew the bottom seam 3/8". Don't sew the side seams, just the bottom.
SewLibra:
When stitching the lining and main fabric together it's good to backstitch, and you can still do the chain technique. Just end your backstitch at the edge of the fabric, make a few blank stitches, continue to the next piece, backstitch, etc.
SewLibra:
Press the lining and main fabric wrong sides together, rolling the lining slightly upward at the seam so it won't show on the right side.
