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How To Make A Fabric Face Mask Cover

How To Make A Fabric Face Mask Cover

When my healthcare friends reached out to me for fabric face mask covers to help extend the life of their actual masks, I asked them if they had any special requests. There was a resounding request for ties over elastic. While elastic masks will happily be accepted, I went to work modifying this awesome tutorial to include ties. Why ties? Ties can be adjusted for each individual to give the mask a better overall fit. 

Face Mask with Ties

Link to original tutorial here:



Face Mask Supplies

Supplies you will need for making your fabric mask:

*Fun quilting cotton for outside of mask

*Muslin or other cotton fabric for pocket 

*twill tape

*cutting mat

*rotary cutter

*flat pins (I love my Unicorn pins!)

*wonder clips

*Mrs. Bobbins spray bottle


*cotton construction thread

*sewing machine 

Side note: If you don’t have any twill tape don’t fret! Grab your Bernina Bias Binder Attachment and let your machine make the fabric ties for you!

Face Mask Cutting Instructions

Step 1. Cut your fabrics. Main fabric measures 10” x 8”, cut one. If you are using directional fabric you will want to make sure you cut accordingly. Lining fabric measures 7” x 5.5”, cut two.

Fabric Mask Lining Folds

Step 2. Make a small fold at the top of both lining fabrics. Sew. No need to back stitch as these edges will eventually be sewn over.

Fabric Face Mask Construction

Step 3. Make sure your main fabric is right side up. Pin both lining fabrics, right side down, in the center of the main fabric. You will want to make sure the unfinished sides are facing you. 

Face Mask with Interior Sewn

Step 4. Sew along both lining fabrics at top and bottom of mask. Make sure to make this more than a 1/4" seam. I used the edge of my foot as a guide. The reason you want this seam a little wider is so there will be enough room when you are threading your ties through.

Face Mask Pressing

Step 5. Now it’s time to step over to your iron and give your fabrics a good press. 

Face Mask After Pressing

Step 6. Flip the fabric over and press again. Your mask should look like this.

Face Mask First Pleat

Step 7. You will want to gently grab both the front and back fabrics to make a fold. Press and pin.

Face Mask Second Pleat

Step 8. Gently grab both fabrics again and make a second fold. Press and pin.

Face Mask Third Pleat

Step 9. Gently grab both fabrics again and make your third and final fold. Press and pin. I know the first few masks this may seem like a frustrating process but once you get the rhythm down it’s very easy.

Face Mask Pleats Back View

This is what your folds will look like from the back.

Fabric Mask Securing The Pleats

Step 10. Now that you have all those lovely folds, you want to keep them in place. Stitch down both sides right next to that lining fabric. I find that this step works best while gently holding the folds in place on each side while feeding this through the machine. That way the folds don’t shift.

Face Mask Front View

Once you’ve stitched down both sides your mask should look like this.

Face Mask Pressing

Step 11. Hop on over to your iron and fold your edge in until it touches that stitch line. Press.

Face Mask Sides Second Fold

Step 12. Fold over again and press. Grab two clips to hold your fold in place. 

Face Mask with Clipped Sides

Both sides should look like this.

Face Mask With Sides Sewn

Step 13. Sew down the edge. On this step you will want to back stitch at the start and end since this is the main stitch that keeps the mask together.

Face Mask with Both Sides Sewn

Both sides should look like this.

Face Mask Front View with Sides Sewn

Now that your mask is sewn you can take out those pins. All those folds might make the pattern on your fabric look a little silly! Not to worry, once the mask is on, the pattern will show properly again.

Face Mask Twill Tape

Step 14. Cut two pieces of twill tape 36” each or use your Bernina Bias Binder Attachment to create fast folded fabric ties. You will want to use your bodkin for this next step.

Bodkin Pulling Twill Tape Through The Face Mask

Step 15. Thread your twill tape/fabric tie through your bodkin and pull through the side “pocket”.

Face Mask Ties with Knots

Step 16. Once the twill tape/fabric tie is through, put a small knot at each end.

Finished Face Mask

Your mask is done!

Finished Face Mask Front ViewFinished Face Mask Side ViewFinished Face Mask Back View

And there you have it, a modified addition to an already fabulous pattern. 

Christine Tanabe - 03 Apr 2020 @ 01:12
This makes so much sense! Thank you for the pattern and instructions!

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