Introduction: EPIC Shaped Face Mask - No Gaps

This is a home sewing tutorial for a double layered face mask for community use. Since march, I've sewn hundreds of masks from dozens of patterns only to keep finding the same fit issues over and over again.

Obviously, there is no such thing as one size fits ALL - but these patterns should fit most as is, if you need to make it smaller for a child or someone with a narrow face, try increasing the seam allowance to make a smaller mask.

If you need it bigger, you can draw around it. There is a 1 inch square for your reference when printing.

I'm pretty sure the license is set to allow you to use this pattern commercially. I don't think any of us are getting rich off facemasks. But if you do get rich off this pattern and process, remember me fondly and throw a little my way. I have benefitted from a wealth of donated materials, and I continue to distribute masks to my community at no cost.

My cashapp is $mrsmitzelplix, venmo @Caroline-Louise


Good Quality woven cotton - around 1/2 a yard. 1 fat quarter will make one layer.

quiting cotton or high quality bedsheets. If you have doubts about your fabric, try the spray test.

Elastic - 14 to 20 inches

For ear loops 1/8 in is ideal, but you can use up to 3/8 in if you have to. You can also use ties if you prefer, but still attach them at an angle. That's part of the key to good fit. 2 pieces of 5" to 7" If you want a single around the head elastic, you'll want 3/8 to 5/8th. I have not tested it with wider. 15 to 20 inches. Better to cut generously if you can.

Sewing machine with thread and needles and all that jazz.

Printer and paper. If you don't have a printer, you can open the image and zoom in until the 1 inch box is one inch and lightly trace the pattern from your screen. Which I have absolutely resorted to, as printers are specifically designed to vex humans.

Step 1: Print/Trace Your Pattern

If you are printing the jpg, you may need to increase the size. The PDF should print at 100%.

Step 2: Cut 2 on the Fold

Cut 2 of the pattern piece on the fold. In this tutorial, it is the same fabric. You can use different fabrics, or sew one piece right sides together and one piece wrong sides together. It helps you keep track of which side is the germy side.

Step 3: Nose Dart

Starting at the upper corner of the nose, sew down the to fold. I use a seam allowance of 1 presser foot, straight stitch, needle in center position.

Step 4: Chin Dart

Flip the piece over and sew along the bottom curve to the fold. I sincerely find that sewing from the open end to the fold makes a more consistent shape. But you do you.

Step 5: Do It Again for the Second Layer.

You should now have 2 pieces that are pretty much the same. At least enough the same to make it up on the seams.

Step 6: Put the Layers Together.

I like to start by lining up my nose darts. I don't clip or press seams open. I lay the seams in the same direction and call it a day. You can use sewing clips or pin. Personally, I hate pins. If you are clipping, clip at the nose seam. Then line up your chin darts and clip them together.

Step 7: Sew the Top Seam

Starting at the back edge, sew towards the nose peak. As you approach the center, where the seams are, slow down. When you get to the peak, lift the presser foot and rotate the mask so you're sewing down the curve on the other side of the nose. It helps keep the shape if you let the fabric cup upwards while you sew.

Step 8: Sew the Bottom Seam.

Same deal, start from the cheek side, let the fabric cup upwards, and just follow the curve.

Step 9: Turn and Finish

Turn the mask right side out, and line up the edges. Fold in the cheek side a bit, and start topstitching. When you get to a corner, lift your presser foot and turn the mask. Sew ALL THE WAY around.

Step 10: Attach the Elastic.

Head band style

If you are using a single head band, cut to desired length (12 inches is generally the minimum, 14 fits the most people reasonably well) and attach right at the corner. (the elastic should be angled up like it's cutting the corner in half. when you sew across the elastic you'll basically make the base of a triangle with that seam.) The elastic should go above the ears and around the head. Snug, but not tight. The elastic should have to stretch a bit to put on. 3/8 in to 5/8in wide are all I've tested. Be careful not to twist the elastic when you are attaching the other side. It's not confortable. If you aren't sure how long, just cut generously, attach one side and include a safety pin. Or cut generaously and suggest they knot it to lenth.

Ear Loops

Cut 2 elastics, 5" for smaller faces (tweens, teens, petite adults) 6" for most adult women, and 7" for most adult males. Alternatively, 8" is enough for most people to tie a knot in the elastic for their custom length. Attach at the same angle top and bottom.