Jordan Ellis
Sewing your own hospital face mask is a great way to help protect healthcare workers and patients during a mask shortage. While fabric masks are not a substitute for N95 masks, they can be used in times of emergency when shortages take place. They can also be worn over medical masks for added protection. It is important to note that cloth fabric masks are not as effective as medical-grade masks and do not eliminate the risk of inhaling infectious particles. However, they can be useful in reducing the odds of inhaling these particles. Before sewing a large batch of masks to donate, it is important to check with your local hospital to ensure they are accepting donations and that your masks meet their guidelines.
Characteristics and Values Table for Sewing a Hospital Face Mask
| Characteristics | Values |
|---|---|
| Materials | Cloth fabric, cotton, elastic, pipe cleaner, garden wire, ribbon, interfacing material |
| Number of Fabric Layers | 2 layers of heavyweight "quilters cotton" with a thread count of at least 180 |
| Dimensions | 9" x 6" rectangles for adult masks, 7.5" x 5" for child masks |
| Sewing Technique | Sew around the mask 1-2 times, secure tucks and pleats, sew over elastic ends |
| Additional Features | Metal strip/garden wire for nose area, pocket for filter, ribbon/elastic ear loops or fabric ties |
| Use | Homemade masks are not PPE but can be used as a last resort or in combination with a face shield |
| Precautions | Masks should not be turned inside out, washed between each use, and not used on young children |
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What You'll Learn
Cut and place fabric
To cut and place the fabric for an adult-sized hospital face mask, first cut two 9" x 6" rectangles of fabric. If you are making a child-sized mask, cut two 7.5" x 5" rectangles of fabric instead. Place the right sides of the fabric (the fabric that will be seen on the outside) together. Pin the fabric in place.
If you want to add a pipe cleaner to the seam of your mask, cut a 4" pipe cleaner for an adult-sized mask or a 3" pipe cleaner for a child-sized mask. Place the pipe cleaner in the seam opening to the opposite side of the mask. Push it up and across the seam and pin it underneath. Fold your opening under to make it even with the side of your mask.
Now, place one end of the elastic in the corner between the two fabrics. The elastic will be sandwiched between the two fabrics, with the rest facing toward the centre of the fabric rectangle. If you do not have elastic, you can use ribbon—cut to 18"-20".
It is important to use two distinct colours or a patterned fabric for the mask so that the wearer can easily identify the front and back of the mask.
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Sew the sides
Sewing the sides of a hospital face mask requires attention to detail and precision. Here is a step-by-step guide to sewing the sides effectively:
Prepare the Fabric Pieces
Begin by cutting two rectangular fabric pieces according to the desired size. For an adult mask, cut two 9" x 6" rectangles, and for a child-size mask, cut 7.5" x 5" rectangles. Place these fabric pieces together with their right sides facing each other, ensuring they are properly aligned. Secure the pieces together using pins to hold them in place.
Start Sewing from the Right-Hand Side
Starting a bit off-center from the top of the fabric's long edge, begin sewing on the right-hand side. Use a backstitch at the beginning to secure the thread. Continue sewing until you reach the first corner, then stop. Place one end of the elastic in the corner, positioning it between the two fabric layers. The elastic will be sandwiched between the fabric layers, with the rest of it facing towards the center of the fabric rectangle.
Sewing the Elastic in Place
Secure the elastic in place by sewing over its ends again. Ensure you maintain a consistent seam allowance, such as 1/4" as you sew around the entire mask. This will ensure that the elastic remains securely attached to the mask.
Creating Pleats
To create pleats, start about an inch from the top of the mask and fold your pleats up, maintaining a height of about 1/4". Secure the pleats with pins to hold them in place temporarily. You should aim for a total of three pleats on each side of the mask.
Sewing the Pleated Sides
Carefully sew along the sides of the pleats, removing the pins as you go. This will secure the pleats in place and give structure to the sides of the mask. Ensure you are using a thread color that matches your fabric for a neat finish.
By following these steps, you will have successfully sewn the sides of a hospital face mask. Remember to refer to online tutorials or patterns provided by hospitals for additional guidance on creating these masks.
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Secure with elastic
To secure a hospital face mask with elastic, you will need two elastic strips measuring 1/8" x 6” for women, 7” for men, and 5” for children. You can also use hair ties as elastics, which go around the ears.
To make fabric ties, cut a strip of fabric 1-1/2” x 18-20”. Fold one short end 1/4” in and sew. Next, fold the fabric strip long edges in so they meet in the center, then fold in half lengthwise again. Sew down the open edge to secure. Place the tie with the raw edge next to the corners of the mask just like the elastic is shown in the video. Make sure not to sew over the loose end of the tie as you sew around the mask.
You can also use elastic straps, which can be secured to the face with buttons, or a headband ear saver with buttons.
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Identify the front and back
When sewing a hospital face mask, it is important to be able to identify the front and back of the mask. This is crucial for safety reasons, as the mask wearer must be able to identify the correct side of the mask at a glance.
One way to ensure this is by using two distinct colours or patterns of fabric. The fabric that will be seen on the outside, or the "right" side, should be placed together, pinned, and sewn. This will result in the "wrong" side of the fabric facing out on one side, which will help the wearer identify the inside of the mask.
Another way to distinguish the front from the back is by paying attention to the rubber band joints. The rubber band joints should be on the outside, while the seamless side should be on the inside. Placing the rubber band joints inside will create a gap between the mask and the face, allowing dust, germs, and viruses to enter.
Additionally, some masks have metal strips on the bridge of the nose, which can be pressed with the index fingers to ensure a close fit to the face. This can also help the wearer identify the top of the mask.
It is important to note that only one side of the mask should be used, as the other side may become contaminated with germs. The mask should not be turned inside out, as this will place the contaminated side against the wearer's face.
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Wash and reuse
Cloth face masks can be washed and reused over and over. They are not medical-grade, but they do provide some protection against the spread of COVID-19. Cloth masks can be washed in the same way as your clothes, using hot water and soap. You can wash them by hand or put them in the washing machine. Wash your cloth masks after each use, and pick a setting that ensures a thorough clean.
It's important to handle your masks carefully when putting them on and taking them off. Wash your hands before putting on a mask, before taking it off, and after you take it off. Try not to touch the front of the mask, as this is the most contaminated part. When removing the mask, take the straps off first, then remove the mask without touching the front.
To store your masks, keep them in a clean, dry place. Don't put them in pockets or bags, as they will pick up dirt and germs. You can also hang them up to air out between uses.
Cloth masks should be swapped out regularly, ideally after 20-30 washes, or sooner if they are damaged or falling apart. Check for wear and tear, such as frayed edges, holes, or broken straps, as this can affect the mask's ability to seal and filter properly.
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Frequently asked questions
Sewing a hospital face mask helps to reserve medical masks for healthcare workers. It also helps to protect yourself and others from large, infectious particles.
It is recommended to use cotton, as it is breathable and did very well in tests. You can also use cotton flannel, pillowcases, or cotton t-shirts. For the ear loops, you can use elastic or ribbon.
Contact your local hospital to ensure that they are accepting sewn face masks and that your masks meet their guidelines. Organisations such as Masks for Heroes also have a searchable database of facilities currently seeking donations.
There are many online tutorials available, including written and video guides. You can also find downloadable patterns to help you get started.
