DIY Dust Mask

The current world health crisis is like nothing we have ever seen before in our lifetime. All we can do is try to stay calm, practice social distancing, and keep ourselves healthy in mind and spirit.

Something is Better than Nothing

A few days ago, I started making masks for my immunocompromised friends, (myself included) because of the critical shortage of protective masks even in the medical community. There’s a lot of mixed information going around about them, and some say they are not effective at all. I really do believe that some protection is better than none, even if it’s to protect myself from touching my nose and face!

I’m Not a Seamstress

There are a few mask patterns available online but they were much too small for the average American adult. I crafted one that should fit most. If you don’t own a sewing machine you can make these masks with a needle and thread. I am not a seamstress. In fact, I don’t really like sewing! Don’t be discouraged if you struggle to make the first mask or two. The small size and curvy lines make it more difficult to sew, especially for people who don’t sew. Practice makes perfect!

Supplies

Cotton Fabric (fat quarters, sheets, muslin, tea towels)
Cotton thread
Sewing machine or hand needle
1/8″ wide elastic or 2mm elastic beading cord
One or two plastic with metal wire twist ties
Hepa vacuum cleaner bag
Download the mask pattern here
I am a six-foot-tall woman, and this is a perfect fit for my face. Be sure to set your printer at 100 percent before printing the pattern. If the pattern looks too small or large for your needs, then add or subtract 1/2″ all the way around the edge of the pattern.

Instructions

Wash, dry and iron your fabric first. Put the right sides together and cut two pieces for the main part, and two for the liner. Sew a 1/4″ seam along the center of the two pieces. Cut small slits along the curved edges with scissors carefully not to go past the seam line.

Sew a top stitch over the top of the seam on the right side. This will make the mask strong enough to withstand repeated washing.

Put the two sections together right sides facing each other and secure with pins or clips to hold in place. Sew a 1/4″ seam along the top and bottom edges. Turn inside out and press with a hot iron.

I forgot to cut the liner section a bit shorter on one side to create room for the insert pocket but was able to do so after stitching. It will be much easier to cut the liner section an inch shorter before sewing! After making a few of these now, I think it will be even better to cut the liner (white fabric) 1″ shorter to both sides to make it easier to insert the filters.

Sew a hem on the white fabric. In this example, there is only one side hemmed, but I will encourage you to do both sides!

Sew a seam about 1/8″ wide all the way across the top of the mask. This is where you will insert the twist tie wire. It needs to be wide enough for the tie to go through but not too wide for it to slide around. It needs to be a snug fit. Sew a topstitched seam on the bottom of the mask too.

Insert the twist tie into the slot into the top of the mask. Be careful, they can be sharp! You may want to bend the ends a little before inserting it into the mask. In this example, the twist tie went all the way through so I could center it across the nose area. In earlier versions, the twist tie would not go all the way through so I used two ties which actually made the mask more moldable to my face shape.

Sew a 1/4 casing seam on both sides of the mask for the elastic. Cut around 10″ of elastic and insert into the casing using a small safety pin.

Try the mask on and tie a knot in the elastic to allow for a snug fit over the ears. Once the knots are tight and secure, you can hide them in the casing.

Update!

I’ve made quite a few of the masks with each one becoming better and easier to make. I found the filter insert a bit difficult to insert with a pocket on only one side, so I have another option.

To make filter insert pockets on both sides trim the liner 1″ shorter on both sides and stitch a small hem them once you have sewn the two main parts together. Hold off on sewing the elastic casings until you have inserted the nose wire.

Having a removable filter material will increase the effectiveness of the mask exponentially but it’s not designed to filter viruses. I purchased HEPA filter canister vacuum bags and found them to be lightweight and very breathable. These alone would probably make great masks to filter out dust and allergens without the fabric but I want things pretty, don’t you?

Cut two pieces of the filter medium 1/2″ smaller all around than the fabric. I created another pattern by cutting it smaller than the original. Sew the two pieces right sides together just like the fabric. Sew all around to keep the layers together.

Insert the HEPA filter into the mask for greater protection. Make sure to throw away the insert and sanitize the mask by washing in approved detergents. Let it dry thoroughly before using again.

If you think wearing a dust mask will help and know people who need them, please share this post with your friends. Most of all, stay well and be kind to one another!