Homemade Face Masks
So you want to make masks for yourself, family, or to donate? First you wanna know what type of mask:
[id: people wearing four different mask types: pleated, olson, 3D, and rectangle]
Rectangle is the easiest to sew imo, and next to the pleated mask will fit most universally. It’s a simple rectangle at 10″x8″ (25.5cm x 21cm). It can be difficult to fit snugly (my sister finds it gets in her mouth when she talks), but once you get the hang of it, it’s very comfortable.
Pleated probably comes in second for ease of cutting and sewing. 9″x6″ (23cm x 15.5cm). It seems to take a lot of ironing. I have not personally sewn this one yet.
3D is 10″x7.5″ (26cm x 19cm), then mark 2″ (5cm) in both directions on all corners and cut off triangles. I had to alter this for myself and my sister to be 1.5″ corner cuts on the top, and two other sisters need smaller dimensions for a comfortable fit. (Sewing machines might also have a difficult time with this, because you sew through 8 layers of fabric in this tutorial but up to 16 in others--use a denim needle.)
The Olson doesn't seem to stay on people's faces well when they talk, but many people like the style so ymmv (I suspect a nose wire is critical). Its measurements are variable and seem to be a case-by-case basis. You need a template for this. I haven’t sewn this one for that reason.
Fabric: use pre-washed 100% cotton or a high cotton blend (95%+), and go for lightweight fabrics before thick ones (like flannel) which will contain more heat. Two layers of filtration is about as effective as you’ll get with cotton, though some people like extra. For the rectangle, pleated, and 3d, you can have one long strip of fabric instead of two different cut pieces.
Nose bridge: Use 20 gauge for your nose piece. It’s harder to form than the popular 16 gauge, but it will hold its shape better and is less likely to break. You need something to cut it with (wire cutters, cheap scissors, garden prunes) and pliers to bend the ends in. Make the wire as long as much as possible--that way, you can get a seal on the top, which makes it safer and keeps glasses from fogging up!
Fastening: tie-behind the head, or elastic over the ears, or elastic behind the head? tie-behind is generally more comfortable (and can be worn longer, if you’re making this for nurses) but some people don't like it. Elastic is good for kids so it's easy to get on. A great tie material is jersey knit fabric (as shown here) cut into .75″ (2cm) strips.
Filters: Given that a mask is to protect other people by catching droplets as they leave your mouth, less to protect yourself from an aerosolized virus, I don’t know how much a filter helps. (To protect themselves, nurses undergo rigorous testing to ensure their masks have a full seal; that’s probably not something you can realistically achieve at home.) Adding a pocket for a filter makes sewing more difficult and reduces how long you can comfortably wear a mask. Do not use anything containing fiberglass as a filter!! Fiberglass particles can do damage to your lungs and give you cancer!
Masks for nurses: use two colors of fabric (I think light on the inside is preferable?) so it’s easy to quickly know which is the wrong side of the mask, and make them tie-behind. Homemade masks are usually worn over other PPE like an N95 to attempt to make disposable masks last longer.
