Crafting Hospital Masks: A Step-By-Step Guide

During the COVID-19 pandemic, there was a shortage of essential medical supplies such as ventilators and face masks. As a result, some hospitals asked the public to make masks for them. People with sewing skills were encouraged to make masks for their local hospitals. Some hospitals provided patterns and instructions for making masks. Homemade masks are not considered PPE, but they can be used as a last resort in settings where face masks are unavailable.

What materials are needed

Making a hospital mask requires a few basic materials that you may already have at home. Here is a list of what you will need:

• Fabric: You will need two types of fabric to make a hospital mask. The first type is for the main body of the mask and you can use cotton fabric, preferably a tight-weave cotton that is breathable and comfortable. The second type of fabric is for the filter, and you can use a cotton-polyester blend, or a cotton-silk blend.
• Elastic: You will need elastic to secure the mask to your face. Look for 1/8-inch wide elastic bands that are soft and flexible. You will need enough elastic to cut into two pieces, each about 7 inches long.
• Needle and Thread: A needle and thread are necessary for sewing the mask together. You can use a sewing machine if you have one, but it is also possible to sew the mask by hand. Choose a thread colour that matches your fabric for a seamless look.
• Scissors: A sharp pair of scissors will be needed for cutting the fabric and elastic to size.
• Filter Material: To add an extra layer of protection to your mask, you can use a filter material such as a coffee filter, or a piece of cotton-polyester or cotton-silk blend fabric.
• Pattern: You will need a pattern to cut out the fabric for your mask. You can find free printable patterns online, or you can create your own pattern by tracing around a mask that you already have.
• Pins: Straight pins will be useful for holding the fabric in place while you cut and sew.

With these materials gathered, you will be well on your way to creating your own hospital mask.

Cutting the fabric

To make a hospital mask, you'll need to start by cutting your fabric to size. For a standard adult-sized mask, you'll want a piece of fabric that measures about 16 by 6 inches. If you're using a thinner fabric, you may want to double it up for added protection, so cut out two pieces of fabric. You can use any type of fabric you have on hand, such as cotton, linen, or flannel. Try to avoid fabrics that are stretchy or slippery, as they will be more difficult to work with.

Once you have your fabric, fold it in half, lengthwise, and press it flat with an iron. This will create a crisp fold down the center of your mask, making it easier to shape and fold. Now, you'll need to cut the fabric for the ties or elastic that will secure the mask in place. Cut two pieces of fabric for the ties, each measuring about 18 by 2 inches. Alternatively, you can use elastic bands, which you can insert into the mask without needing to cut fabric ties.

If you're using elastic, cut two pieces that are each about 7 inches long. You can adjust this length to suit your face and head size. Next, you'll want to cut a piece of wire that will be inserted into the top of your mask so that it can be moulded over the bridge of your nose for a snug fit. The wire should be thin and flexible; you can use pipe cleaners, twist ties, or floral wire. Cut the wire to be about 6 inches long, or slightly shorter than the width of your fabric.

Finally, if you want to add a pocket to your mask for a removable filter, cut a piece of fabric that measures 4 by 6 inches. This will be sewn onto the back of your mask, creating a pouch where you can insert a disposable filter.

Sewing the mask

To sew a hospital mask, you will need fabric, elastic, a needle and thread, and a sewing machine.

Start by cutting your fabric to the desired size, usually a rectangular shape that can comfortably cover your nose and mouth. You will need two layers of fabric for the mask, so cut out two rectangles of the same size.

Next, place the two pieces of fabric on top of each other and fold over the longer sides of the rectangle, creating a pocket for the elastic to be inserted. Sew along the fold to secure the elastic in place. You can use a sewing machine or hand-stitch this part, ensuring a secure hem to hold the elastic in place.

Now, take the elastic and cut it to a length that will comfortably fit over your ears when worn. You will need two pieces of elastic, one for the top and one for the bottom of the mask. Insert each piece of elastic into the pockets you created earlier, and sew the ends of the elastic to the mask, backstitching to secure the thread.

Finally, sew the two pieces of fabric together along the remaining sides, enclosing the elastic within the mask. Leave a small opening so that you can turn the mask inside out, then hand stitch the opening closed. You can add additional stitches to the mask for reinforcement or to create a more fitted shape.

Your hospital mask is now complete and ready to be worn.

Adding ties

To make a hospital mask, you'll need to gather some supplies, including fabric, elastic bands or ties, and a sewing kit. One way to make a hospital mask is to follow these steps:

Cut a long strip of fabric that will serve as the ties. The strip should be about 1.5 to 2 inches wide and long enough to comfortably tie around your head. You can adjust the length as needed. Fold the strip of fabric in half lengthwise and iron it flat. Sew along the open edge, creating a tube. Turn the tube inside out and iron it flat again. This will be your tie. Repeat this process to create a second tie. Pin the ties to the top corners of the mask, with the raw edges aligned. Sew the ties securely in place, making sure to reinforce the stitching to ensure they don't come loose. You can also add additional ties to the bottom corners of the mask for a more secure fit. To do this, simply repeat the process and attach the ties to the bottom corners. Try on the mask and adjust the ties as needed to ensure a comfortable and secure fit.

Testing the mask for fit

Once you have made your hospital mask, it is important to test its fit to ensure maximum protection. Here are some steps to help you test the fit of your mask:

• Put on the mask: Place the mask over your nose and mouth, ensuring it fits snugly. Adjust the elastic bands or ties to secure it in place.
• Perform a seal check: Cup your hands over the mask without touching it and exhale gently. If done correctly, the mask should slightly inflate. This indicates that the air is mostly escaping through the mask filter rather than around the edges, creating a seal.
• Try the fit and breathability test: With the mask on, inhale and exhale sharply. The mask should remain in place without shifting or leaking air from the sides. You should be able to breathe comfortably without feeling restricted.
• Check for gaps: While wearing the mask, move your head up and down, side to side, and try talking or smiling. Ensure that the mask maintains its position and that there are no gaps between the mask and your face.
• Conduct the flame test (be cautious): Light a candle or a lighter and hold it about 6 inches away from your face. With the mask on, try to blow out the flame. If the mask fits properly, you should not be able to extinguish the flame easily. The air should go through the mask, not around it.
• Consider using a mirror or seeking assistance: When testing the fit, use a mirror to observe the mask's placement and check for gaps. Alternatively, ask a friend or family member to help you assess the fit and identify any areas of leakage.

Remember, a properly fitted mask should create a seal around your nose and mouth, preventing air leakage. If your mask does not pass these tests, adjust the elastic bands or ties, or consider making a new mask with a better fit.

Frequently asked questions