The last week my husband and I have been researching masks to make for nurses and other medical professionals to use, primarily to wear over and extend the wearing time of their N95 respirators. The best mask pattern that we found was one designed by Jennifer Maker (link below). It can be worn alone (not the same protection as N95 respirators), or over the N95 respirators. This link has sizes for small, medium and large.
The site has directions for using a Cricut machine to cut the masks out, and also PDF patterns that you can print off and then cut out. The instructions are very good, with photographs for every step, which makes it easier. This pattern is more fitted than most and includes a wire at the nose to pinch for a closer fit.
I washed and dried all the fabrics first and then lightly pressed them. I found that it was faster to cut out the fabric with my sewing shears, than with the Cricut. You can also make better use of your fabric when you cut them out by hand. Plus if you are cutting them out, you can cut multiple layers at a time. I folded each of the fabrics I was using in half right sides together, then layered one top of the other, so I could cut out 4 layers (enough for 1 mask) at a time. Then when I stitched them together, they were already right sides together. I didn’t pin them, just stitched in a chain, like you were stitching together quilting pieces, except that I did back stitch at beginning and end of each seam.
The directions below have a removable filter pocket made of t-shirt fabric. When we made these, we decided that it made the mask too heavy to wear all day, so we opted to have it stitched into the mask. Depending on your purpose, that might be a good option.
I cut out the outer fabric, inner fabric and filter all the same size. There are several suggestions in the link below for different filters you can use.
You will need to press the seam allowances on the fabric open. This is the most time consuming part, as least to me. Using a roll of paper towels makes this so much easier. Experiment a bit, using different sizes of rolls. A full roll is too fat, a roll that is about 1/2-2/3 used is about right.
Press the outside also. I just used my finger to press the filter open. It doesn’t stay open very well until it is stitched in.
This pattern has a nice curved fit. I found that the assembly line system works most efficiently.
Elastic was not available in our area, so I used ribbon. See the link below for two different ways to tie the ribbons, around the ear or around the neck.
Use a 3/8 inch seam allowance to stitch around the mask, fabric right sides together, and smooth side of the filter against the wrong side of the top fabric. Leave one side open, pull ribbons through that end. Stitch. Trim filter close to seam and angle corners to reduce the bulk. Gently turn right side out, push out corners and press again, rolling seam to middle of the edge.
The fitted nose piece is one of things that makes this mask so much better than most. The directions below have you use 20-22 gauge floral wire, which does work.
My husband noticed on the masks he had that the nose piece was a very thin metal strip. So we set off the find a similar material. These stainless ties were close. I cut them into 4 inch strips and then rounded the edges. These ties make a more comfortable nose guard, because they are flat. When you use the floral wire, you have to coil the end, which makes a slight bump.
These strips are inserted in a channel that is stitched in at the top of the mask. Use the directions in the link, just substituting the wire strip for the floral wire. Turn under the edges of the open side seam and stitch closed.
I reinforced the stitching on the side to make the seam stronger, so that the ribbons wouldn’t pull out. Press one final time. You should be able to put these in the washer and dryer on light to casual settings. They could also be hand washed.
These are the small and large sizes of the masks. Our nurses and medical professionals are working so hard and are under so much stress. Many do not have the PPE that they need to be protected. Please thank your nurses and doctors, along with other medical professionals for all they are doing to keep the rest of of safe. They are AMAZING!!!!
