Respirator / N95 Style Mask from materials @ home

Mask on person
Finished product

After seeing a video from the Czech Republic earlier this week regarding everyone wearing masks as a community to protect one another and hopefully slow the spread of COVID-19, I started looking into making the best cloth mask I could at home with materials I had onsite.  I wanted them to be reusable and not contribute any more trash in the long run than necessary.  

I watched several videos (doctor with t-shirt), (fabric store in Washington State), and (South China Morning Post Experts) to learn what the options were.  I came away with the following ideas:

  1. I wanted something more fitted than a cut t-shirt (it which works, but not my preference)
  2. I wanted a pocket for a filter of some kind that allows even more protection (if the user wants it)
  3. It needed to be made of several different layers to give the most protection possible with a fabric mask
  4. One of the layers needs to be a fused fabric rather than all wovens (shopping bag or interfacing)

So, I found the pattern referenced in one of the videos and I chose to use the pocket version with included seam allowance.  It has good explanations, but I have made a few modifications.

  1. Print out the size you need.  Men’s size is accurate.  Women’s and teenagers is a little big but wearable. I haven’t made a child size yet.
  2. Cut out the pattern.
  3. Modify the interior fabric piece by cutting off the seam allowance.
  4. Tape the seam allowance onto the main fabric pattern piece so that it can fold back and forth.
Modified main fabric pattern piece

Cut the following pieces of fabric in these types of materials:

  1. Exterior fabric in a cotton woven fabric – main fabric pattern piece with added seam allowance
  2. Fused fabric from an inexpensive shopping bag or interfacing – main fabric pattern piece without added seam allowance
  3. Interior fabric for pocket from a cotton t-shirt – modified interior fabric piece
  4. Note – if using interfacing instead of shopping bag – you may want a fourth layer to put on top of interfacing when sewing.  I had a difficult time sewing directly on the interfacing.

Line fabric pieces up as such:

  1. Exterior fabric pieces right sides facing each other
  2. Fused fabric piece on top of exterior piece
  3. Third fabric piece if using
Fabric exterior sandwich before sewing. Flower fabric will be the outside.

Sew along curve with a small seam allowance.  Use a serger if you have it – if not just a regular stitch.  Clip the seam allowance if using a regular machine.  Top stitch the seam allowance down to one side from the inside.

Sew the t-shirt interior fabric in the same manner.  I am not top-stitching it down.  I found it wasn’t necessary.

Interior pocket fabric with right sides sewn together

Make a sandwich with the exterior fabric bundle and the t-shirt interior fabric with the right sides facing.  Sew along the top and bottom with either a small seam allowance or your serger.  I am using the foot and the far-right needle location as my seam allowance with my regular machine.

Turn the mask right sides out.  Top stitch the top and bottom edges to hold everything in place.

Finish the ends of the mask so they won’t unravel.  Turn the fabric over about 5/8 inch to make a sleeve for the elastic.  Sew this sleeve down.  Cut a length of elastic as appropriate – 18 or so for men and around 16 for women and teenagers.  Using a safety pin, thread the elastic into the first side – pin it in place – then thread the other side.  Sew the end of the elastic together and move it to the inside of one of the sleeves.

Wash before first use.

To use:

  1. With clean hands – insert a piece of paper towel and or a facial tissue into the pocket of the mask behind the t-shirt fabric.
  2. Wear.
  3. When you return home from your outing – remove the paper filter material into the trash.  Wash the mask in soap and water after each use.

Mask care, etc. on Masks4All.co

Another one

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