Since the end of March 2020 my quilting has been set aside for sewing masks. At times I crave time working on my quilting and commit to taking a pause from the masks, but then a need or a request arises and I make a pile more of masks. I try to remind myself it is the least I can do to help in this time of craziness. The very least. I am not making 100s of masks… I am no heroic maker of masks. However, it feels good to make a bunch and give them away.
I have tried a few styles and patterns and I thought I would share my favorite patterns and links for the sites I’ve used. I’ve gotten feed back from some about the fit and comfort of the various masks which I will share also.
I started out making the folded and pleated masks until I ran out of my stash of quarter-inch elastic. Then I began making a super comfortable, adjustable mask that used bias tape, which I did not have. However, I found a wonderful, short video on how to make your own without the special tool. I made dozens of these masks and was able to starch them (a lot) and press flat to fit into a business envelop and send one at a time using one first class stamp. Lastly, I found a 3D mask pattern that allows for adjustment and does not take as long to make as the bias tape mask.
Below are the three masks I’ve made with links to each. Following the list I have added more information and links to other sites that gave me ideas or guidance in the construction of each.
- Below are the three styles and patterns I have used:
Folded or Pleated Mask
The folded or pleated mask was one of the first mask patterns offered about the middle of March this year. Since then there are now hundreds of options, styles, patterns, and sizes to choose from. There are also hundreds of videos available for construction guidance. This mask is comfortable if the straps are the right length, but because they are not adjustable I had some reports that the masks didn’t fit well. Recently I started using cotton t-shirt fabric to make stretch cording for the ear loops and pony beads to make the loops adjustable. I think that could be used on this pattern to ensure a better fit. This mask is not as fitted to the face as well as others masks are with metal over the nose or a more rounded style to cup the chin.
This mask is made with a two pieces of fabric 6 x 9 inches. Two pieces of 6 inch 1/4 inch elastic is used for the loops over the ears. Pleats are sewn onto the sides. This mask takes very little time to cut out and construct. Here is the link to RuralOrganizing with a short, complete video on sewing this mask that was posted the middle of March 2020.
Pull Cord Under the Chin Mask (Adjustable)
This is the mask pattern that I have made for my family and friends. This mask is great because a pull cord under the chin, which is made of bias tape, allows the wearer to adjust the size. The mask also rests away from the face so it doesn’t feel close and hot. This mask also includes a wire or piece of metal over the nose to avoid gaps. My husband gave me a thin sheet of aluminum metal that I cut into narrow strips with an old scissors. I’ve read that some use the metal strips from a bag of coffee. Others use wire that they loop at the ends to prevent the wire from protruding out of the mask. This mask has a design that cups around the chin to offer a more fitted feel. I’ve had many say this is the most comfortable mask. However, this mask takes more advanced sewing skills and a bit more time to make.
I like the idea of not having to use elastic, which I understand is still hard to find. I never use bias tape, so I did not have any on hand. I also do not own the tool to make bias tape. However, I found a great Youtube video for making bias tape without a bias tape device. It was fun (but more time) to use the same fabric for the bias tape and the mask. I found making sure the fabric was medium to heavily starched made the process of making the bias tape so much easier.
Assembling mask 
Pull under the chin mask
Link to a PDF pattern and tutorial from Allina Health for a Pull-Cord-Under-the-Chin face mask.
3D Mask (Adjustable & Various Sizes)
Recently I have discovered the 3D Mask style. I find this particular 3D mask to be roomy, comfortable, adjustable, and quicker to construct. I love the children sizes. I have to say the small child mask is adorable. I’ve made this style of mask for a medical clinic where masks for all is required, even on the kiddos. This also had a bendable piece of metal above the nose to tightly secure the mask against the face. Here is the link to the video I watched to make this style of mask. I then drafted the pattern into the various sizes (links below). I like that I can use my rotary cutter to cut out the mask pieces.
I’ve discovered how awesome t-shirt fabric works for the loops over the ears. It’s soft and sturdy enough with a slight amount of stretch. I use pony beads to allow the loops to be adjusted. Both the t-shirt fabric (100% cotton) and pony beads are readily available and inexpensive. Here is a link to a short video on making stretch cording or t-shirt yarn with a cotton t-shirt. I used 3/4 inch strips of t-shirt to make my cord. Here is a link to using elastic with pony beads rather than t-shirt fabric stretch cording.
- Links to PDF patterns 3D Mask
3D Mask – Child SM 
Thin Aluminum Strips 
Ready for assembly 
Pony Beads on T-shirt Cording