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Custom Fit Mask (June 2020)
After sewing many masks since March, I have developed a method to make a custom fit mask using cone shaped coffee filters. I have been using polypropylene shopping bags as recommended by a biomedical engineer at makermask.org, since the beginning. The WHO, CDC, and other agencies are now recommending at least one outer layer of polypropylene fabric which is water resistant, but still breathable. Click through the photos to see my coffee filter method for fitting and developing your pattern, 2 sample patterns you can copy, as well as sewing instructions for shaping without stitching into the body of the mask which will leave needle holes.
Supplies and bag preparation
Shopping bag (Walmart) wire and shoelaces (at least 54 inches long), Dollar Stores. Wash bags with detergent and warm water in washing machine. Air dry or tumble dry on low about 20 minutes. Take bag apart by removing all stitching – binding, handles, top hem, etc. There are usually large stitches, so it goes pretty quickly. Cut threads on one side about every inch, then pull the thread loose on the other side. Binding and handles will be re-used. Do not use any part of bag with needle holes for body of mask. Press flat with a dry iron at medium heat. Place paper towels on pressing surface and use paper towel as pressing cloth to protect iron and pressing surface.
Patterns
No. 2 and 4 coffee filters, paper towel test masks, and the resulting patterns.
Coffee Filter Fitting
I used cone shaped coffee filters to make patterns. Hold filter up to face, placing close to bridge of nose and under chin. Fold back to touch end of nose and chin. Mark top and bottom of ears on sides. No. 2 filter fit me well, No. 4 fit my husband.
Draft the Pattern
Draft pattern from coffee filter, extending sides to desired width. Note small bit reduced on chin.
Paper towel test pattern
Cut out pattern on folded paper towel, cut off darts at nose and chin, tape closed, and try on for fit.
Paper towel test fit
I taped the test mask to my face so I could take the picture. Make any needed adjustments and transfer to pattern.
Sewing instructions
Cut 2-3 layers from prepared polypropylene bag and mark beginning and end of stitching line. I snip mark, no more than 1/8 inch. You can also use pencil or marker. Fold and stitch each layer at nose and chin near edge. The binding will cover this stitching.
Shaping the mask
To form darts, fold stitched edge back on edge of mask and clip in place. Fold inner and outer layers in opposite directions (3rd layer not shown in photo). The folds appear to go in the same direction in the photo, but when green layer is turned right side out, they will be opposite.
Baste layers together
Nest layers and baste together. Make sure darted areas are going in opposite directions. Third layer not shown in photo, but will go in same direction as outer or inner layer. Green is outer, orange is inner layer.
Outer layer
Outer layer after basting together.
Binding and wire
Stitch binding to top and bottom. I reuse the binding holding the bag together. Curl ends of wire in and insert in top of mask.
Side binding
With 1/4 - 3/8 inch seam allowance depending on thickness of shoelace, stitch side binding to back of mask, folding top and bottom ends even with mask. I used the handles from the bag. The sides are already pressed in.
Shoelaces
Place shoelace next to stitching, wrap binding around it, and topstitch in place. Make sure end of shoelace comes out of top of mask. Adjust needle position if your machine allows, or use zipper foot to stitch close to edge. Knot ends of shoelace to prevent pulling out. Shoelaces may shrink after boiling, so do not shorten until boiled, or pre-boil before sewing. To shorten shoelaces, make a knot near desired end and trim excess, leaving about 1 inch. Briefly pass through lit candle or lighter until fibers melt. Let cool before touching.
Susan's Pattern 6/2020
Feel free to copy this pattern as a base for your mask. Adjustments may be needed for a custom fit. For reference, my face is about 6 inches from the bridge of nose to under chin where neck starts, but everyone's contours are different. I think my chin might be a little smaller than average. Allow enough room so that the mask does not move when you talk.
Jim's Pattern
Jim measures about 7 inches from bridge of nose to under chin where neck starts.
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