Pleated Face Mask with straps, filter pocket and nose bridge pocket

COVID-19 has many of us busy making masks. From information gleaned online and my own experience, I have learned that to make a mask useful it needs to provide good coverage, have a space for a nose piece to allow for a snugger fit and have a pocket to allow the insertion of filter material. Masks with straps rather than elastic ear loops are more comfortable for long wear time. Hospitals prefer masks with different colored fabric on the front and back to make it easier to identify which side has been against the face. If possible, lighter fabric colors are preferred to make it easier to see when the mask is soiled.

NOTE: This tutorial may not be suitable for beginner sewists.

This pleated mask, adapted from a combination of the We Can Sew It ("Rosie") mask and Kim's Kitchen Affair's YouTube Video, is an option for hospital donations where a pleated mask provides the needed flexibility in sizing.

Features of this mask: 1) Secured with ties. 2) Nose wire is inserted into a pocket at the top of the mask that is easily accessible. 3) Nearly full width opening at the bottom of the mask allows insertion of filter material.

Because the fabric I purchased online at JoAnn had a looser weave than I felt comfortable with, this tutorial is three layers of cotton woven to compensate. The two layer modification is noted in the instructions.

This tutorial utilizes a serger.

Materials

Two pleat pressing template from Kim's Kitchen Affair's (see size required below and fold the template prior to starting)

For personal use: 4” nose wire (pipe cleaners, floral wires, etc.). Twist/fold in the ends so as not to poke. For hospital use: Only include a nose piece if specifically requested.

Two strips of ½” double-fold bias tape (or two 1 ¾” wide strips of 100% cotton woven fabric folded into bias tape)

o Average adult size: 38" long x2

o Larger adult size: 40" long x2

o Child size: 36" long x2

100% cotton tightly woven fabric: Pre-washed in scent-free detergent in hot water and dried on high. One color for the outer layer of the mask and one color for the inner layer(s).

o Average adult size: Outer: 8” wide x 9” tall, Inner: 8" wide x 8" tall (use medium template)

o Larger adult size: Outer: 9” wide x 10” tall, Inner: 9" wide x 9" tall (use large template)

o Child size: Outer: 5” wide x 8” tall, Inner: 5" wide x 7" tall (use medium template but only do 2 pleats)

Instructions

1. With the outer fabric, serge one short side of the rectangle of mask fabric. Then turn the serged edge in and sew it down. (Note that serging will be with the knife locked throughout).

2. With the inner fabric, lay two inner layer right sides together (RST). Serge along one short side. Turn the fabric wrong sides together (WST) and sew narrow seam along serged edge. (If you are only doing two layers of cotton for your mask, simply serge and hem like Step 1 on your inner fabric.)

3. With RST, align the unfinished short sides of the inner and outer fabric. Serge. Press the seam to the inner fabric side.

4. With WST, align the bottom hemmed edges of the mask. Press the top of the mask (you will have an overlap of outer fabric). Feel for the serged edge beneath the inner fabric, fold the top of the mask down at that edge and press.

5. This top band of fabric will be used to create the tunnel for the nose piece.

Place pins 1 5/8" in from each edge. Place an additional pin 3/4" in from the pin on the right.

6. Start at the left, bottom, sew to the left pin. Pivot and sew toward the top edge of the mask. Either back stitch or pivot 180 degrees and head back to the bottom edge. Pivot and sew along the edge until you reach the second pin. Backstitch a couple times to secure. Cut the thread. Start your next stitch at the top edge where the third pin is. Sew down to the bottom edge. Pivot and sew along the bottom edge to the outer edge.

7. Sandwich the mask between the folding templates. Lay down the first template. Place the mask inner fabric up on the template roughly centered horizontally on the template. Lay the second template on the mask. (Both templates should have the pleats angled up (i.e. if you slide your finger in the pleat you would be coming from the top down not the bottom up)).

8. Fold the top down. Flip it over and fold on the next line. Flip the mask back and accordion the rest of the mask up into pleats. Fold the bottom edge tightly down over the final fold.

9. Secure the pleats and narrow the opening at the bottom to hold filters more securely. Starting from the bottom right corner, start your stitch near the bottom edge 1 1/4" - 1 1/2" in from the right edge. Backstitch a couple of times to reinforce. Sew to the right edge stopping about 1/8" from the edge. Pivot and sew to the top of the mask. Repeat with the left edge. Your pleats are now secure. Remove the pleat template.

10. Now you're ready to attach a strip of bias tape to each side of the mask to enclose the raw edge and form a strap.

11. Mark the halfway point on the length of your bias tape. With the bias tape double folded, turn the end inward and stitch across to hem by starting at the folded edge and sewing in toward the open edge. Pivot and sew down the length of the strip close to the open edge of the strip to secure it into a strap. Stop at the halfway point you have marked. Slide the mask into the bias tape with the top of the mask toward the machine. Tack stitch at the top of the mask, then sew to the bottom of the mask and tack stitch. Continue sewing to secure the tape to the mask and complete sewing to the end of the strap. Turn the end inward and pivot to hem the end.

Congratulations on completing your mask!

If you are inserting a nose wire, slide it into the 3/4" opening at the top. In this example, I have taken an 8 inch piece of craft pipe cleaner, folded it in half, twisted the wire to secure the two halves together and then folded in the sharp ends. The pipe cleaner should be removed before laundering.

I include the following letter with my masks when delivering to individuals.

Mask was packed on _____________________ at ________________

Thank you for all you are doing to keep others safe during this pandemic including practicing safety measures recommended by our governor and the CDC.

The enclosed mask(s) are not medical-grade and no medical or health claims are being made. Please review the CDC guidelines for best practices for cloth face coverings.

As of April 13, 2020, the CDC recommends that regular machine washing will sufficiently clean your mask. Individuals should be careful not to touch their eyes, nose, and mouth when removing their face covering and wash hands immediately after removing.

Please wash your mask before first use. Prior to washing, remove any nose bridge wires or filter materials you have added. Your mask will withstand washing in hot water and drying on high heat. I personally do not use fabric softener as that can affect the breathability of the fabric. If your mask has cloth ties, secure the ends in a bow before washing to help prevent the tie being pulled through.

Your mask has a tunnel of fabric across the nose piece that allows you to insert a wire if you require a snugger fit. Wires should be curled on the ends so as not to poke. A filter material can be used between the layers of the mask, if additional filtration is desired. Cut the filter material down to size and slide into the pocket. Wire and filter material recommendations are constantly changing, please utilize a web search for options.