After reading about shortages of masks for medical and essential workers here in San Francisco, I began researching materials and methods for creating DIY masked with household materials with the intent of donating finished masks. Now that I have completed a handful of masks, I wanted to share completion steps in inspiring others to do the same.
Most of the following steps were inspired by and/or credited to the following websites:
Creation Process:
Materials Used:
Materials Needed
Fabric
Vacuum bag filter: 2x - 9 in x 6 in rectangles
Tight woven cotton: 2x - 9 in x 6 in rectangles
Hardware
sewing machine
Universal sewing needles
thread
scissors
tin snips
elastic - Adult Standard size: 2 x - 7 in pieces
elastic Adult Standard size: 2 x- 6 in pieces
2x -3 in bendable wire
1x - 3 inch piping
Why vacuum bags?
Studies have shown this DIY material best filtered 0.02 micron Bacteriophage MS2 particles. 5 times smaller than the coronavirus. Vacuum bags are effective, but note, the stiffer the material, the less form fitting and effective the mask may be. Be aware of this when deciding which materials to use. Additionally this may make these masks less or non re-usable. There is no evidence that these bags would stand up to washing. If this is concerning, skip the vacuum bags and go for cotton only.
Any type of elastic for around the ears will do. Depicted are a few options.
Hair Band elastics
Thin elastic banding
Thick Elastic banding
Bendable wire is preferred as this will fit over the bridge of the nose. Types of wire as follows:
Cloth Stem wire
Bendable Craft wire
Instructions
1. Cut vacuum bag into 2x - 9in by 6in rectangles.
Note: Ideally the vacuum bag is as pliable as possible. The stiffer the material, the less form fitting and effective the mask!
2. Cut cotton into into 2x - 9in by 6in rectangles.
Note: To test whether your fabric is tightly woven, hold it up to the light. If you can see through it, its loose. For this demo,this is less concerning since the vacuum bag is our predominant filter.
3. Put wrong side of fabric against vacuum filter material.
4. Pin in place. This is in preparation of baste stitching
5. Baste stitch materials together along all four edges.
Detail image of Basting Complete
6. Once the basting is complete, its now time to use the second piece of cotton fabric. Turn basted material over and place right sides of fabric pieces together.
7. Pin in place.
8. Starting in the center of one of the 9 in edges, begin a straight stitch, stopping a few inches before the end of the edge as seen above.
9. Insert one of the 7 in pieces of elastic at a 45 degree angle inside the first corner.
10. Sew in place.
11. Turn the corner and continue sewing down the first 6 in edge, again stopping a few inches before the corner.
12. Find the remaining edge of the elastic and place it at a 45 degree angle in the second corner.
13. Sew in place.
14. Sew around the edge.
15. Repeat steps 9. 10. and 11 for inserting elastic on the remaining corners.
16. After turning the last corner, stop short of completing the loop so a gap remains between the fabrics. This will be used to turn the fabric right side out.
17. Turn the fabric right side out. This takes a little patience. Use the elastic to gently pull the fabric through the opening.
Detailed image of what the right side of the mask looks like once the fabric is reverse.
18. At this point you may want to iron the fabric in place. This is helpful to form the seam at the remaining hold yet to be sewn.
19. Next its time to pin the fabric in preparation for sewing. Pin the fabric at the open gap and first tuck.
Detail image of tuck.
20. Three tucks total on each side. Try to align the tucks evenly across the mask.
21. Next begin sewing the tucks in place with a straight stitch. This is when the sewing can get a bit tricky. I prefer sewing the straight edges first, then sewing the tucks.
22. When sewing the tucks, I've found you need to guide the fabric fairly heavy handedly. Be careful to avoid hitting pins!
Detailed image after all edges sewn!
Additional Fitting Instructions
Below you'll find instructions to improve fit around the bridge of the nose.
Materials
2x -3 in bendable wire
1x - 3 inch piping
23. After cutting 1x 3in strip of piping ribbon, insert 3 inch piece of wire.
24. Find the center of the top inside of the mask. Pin the piping or ribbon in place.
25. Straight stitch or zig zag stitch the piping in place. Careful to avoid hitting the wire!
25. Turn the corner and change stitch type to zig zag. I prefer to stitch up and down each of these edges twice for security.
26. Repeat on the other side.
Note: For my mask, I did not need to stitch down the bottom edge, however it may be necessary to do so depending on materials used.
Completed mask!
CDC Advisory for usage
"In settings where facemasks are not available, HCP might use homemade masks (e.g., bandana, scarf) for care of patients with COVID-19 as a last resort. However, homemade masks are not considered PPE, since their capability to protect HCP is unknown. Caution should be exercised when considering this option. Homemade masks should ideally be used in combination with a face shield that covers the entire front (that extends to the chin or below) and sides of the face."
