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Non-Pleated Face Mask With Filter Pocket

As more of us are looking to make our own fabric masks to wear in public to help prevent the spread of the COVID19 virus, there are a couple of typical types. This page contains a tutorial for making the non-pleated style with a pocket for adding a filter such as a folded coffee filter.
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The most recent orders from our governor include wearing masks when in public so I decided to make a set of masks for my family. I found a free pattern online for a non-pleated mask with filter pocket.

Supplies:

Editor's Note: If you are attempting this project for the first time please note that the original mask pattern has been slightly revised, version #3. You will note that the seam allowances are now set at 3/8ths inches rather than 1/4". The designer has also added an additional fabric allowance on the tab for the mask to accommodate wider elastic or ties. The steps are essentially the same as those published here.

Steps:

  1. Download, print, and cut out the template in the size you need. This version has a main piece and a liner piece.
  2. Fold your fabric, wrong sides together, then pin the main pattern piece to the fabric. Repeat for the liner pattern piece. You should now have 2 pieces for the main layer and 2 pieces for the liner layer.
  3. For the main layer, pin the fabric pieces right sides together. Then sew along the curved edge using a 1/4" seam. Remove pins and tie off thread. Repeat for the liner layer.
  4. Clip along the curve every 1/2", making sure to not cut through the seam.
  5. Press the seam to one side and top stitch. Do this for both the main and liner layers.
  6. For the liner layer, fold the side in 1/4", then fold over again and press. Now sew in place with a 1/8" seam. Repeat on the other end.
  7. Place the liner layer onto the main layer, right sides together. Pin along top edge and sew with 1/4" seam. Then pin and sew the bottom edge with a 1/4" seam. Tie off thread ends.
  8. Clip top curved edge. Turn mask right side out and press seams flat.
  9. Clip the edges of the main layer where it is sewn to the liner layer, as shown below. Fold it under 1/8" and then fold again. Pin in place and topstitch from one end to the other, repeating on the bottom edge.
  10. Fold the end of the main layer over 1/4" and press. Then fold the end over to the edge of the liner layer. Pin in place and sew with 1/8" seam. This creates the little pockets for the elastic. Repeat on the other side.
  11. Insert elastic and tie. Try on the mask and make sure the elastic holds it tightly to your face, adjusting if necessary. Then gently pull it so that the knots go inside of the mask pocket.
  12. Filter Pocket: This mask has an optional filter pocket. One option is to insert a folded coffee filter into the pocket.
  13. You can also opt to use a long, continuous piece of elastic so that it goes around your neck and head. This is a good option if you find that the other hurts your ears. Make sure to try it on and adjust the length of the elastic so that the mask is held tightly against your face. Then pull the elastic until the knot is hidden in one of the pockets.
  14. The pattern I chose also had 2 different sizes for children. For my son's mask I decided to use 2 different coordinating fabrics for the outer layer which turned out really cute!
  15. The pattern also offered patterns for teens/women and adult men. Here is the one I made for my husband to wear at work.
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