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Non-Pleated Face Mask With Filter Pocket

Non-Pleated Face Mask - child's mask from the side
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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April 30, 2020

Non-Pleated Face Mask - women's over the ear mask made with pink fabric with cherry motifThe 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. Non-Pleated Face Mask - printed pattern cut out
     
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  3. 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.
  4. Non-Pleated Face Mask - pattern pinned to main fabric and cut out
     
    Non-Pleated Face Mask - pattern lying next to the two pieces from main fabric
     
    Non-Pleated Face Mask - pin lining pattern to fabric
     
  5. 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.
  6. Non-Pleated Face Mask - pin curved edge of main fabric together right sides together
     
    Non-Pleated Face Mask - sew a 1/4 inch seam
     
    Non-Pleated Face Mask - pins removed, tie and trim thread, repeat with lining
     
  7. Clip along the curve every 1/2", making sure to not cut through the seam.
  8. Non-Pleated Face Mask - clip curve at 1/2 inch intervals, repeat with lining
     
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  9. Press the seam to one side and top stitch. Do this for both the main and liner layers.
  10. Non-Pleated Face Mask - press seam to one side on both main and lining assemblies and top stitch
     
    Non-Pleated Face Mask - topstitching on lining
     
    Non-Pleated Face Mask - both pieces done
     
  11. 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.
  12. Non-Pleated Face Mask - fold in 1/4" on the straight side of the liner, fold in again and press, repeat on other end
     
    Non-Pleated Face Mask - second fold
     
    Non-Pleated Face Mask - stitch on machine
     
    Non-Pleated Face Mask - tie threads and snip
     
    Non-Pleated Face Mask - view of the liner with ends sewn
     
  13. 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.
  14. Non-Pleated Face Mask - pin the liner piece to the main piece with right side together
     
    Non-Pleated Face Mask - sew a 1/4" seam
     
    Non-Pleated Face Mask - seam sewn and pins still in place
     
    Non-Pleated Face Mask - pulled back photo of this step completed
     
    Non-Pleated Face Mask - tie threads and cut
     
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  15. Clip top curved edge. Turn mask right side out and press seams flat.
  16. Non-Pleated Face Mask - clip curved seam allowance
     
    Non-Pleated Face Mask - turn right side out and press seams flat
     
  17. 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.
  18. Non-Pleated Face Mask - clip edge of main piece next to edge of liner as shown
     
    Non-Pleated Face Mask - fold in 1/8" and then fold again and pin
     
    Non-Pleated Face Mask - pins in main end tab and across the top of the mask, topstitch
     
    Non-Pleated Face Mask - repeat on the other side
     
  19. 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.
  20. Non-Pleated Face Mask - fold in end of main piece 1/4"
     
    Non-Pleated Face Mask - fold again to rest right up against the liner and pin
     
    Non-Pleated Face Mask - sew along the folded main piece 1/8" seam, this creates the channel for the elastic
     
    Non-Pleated Face Mask - repeat on the other side
     
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  21. 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.
  22. Non-Pleated Face Mask - insert elastic
     
    Non-Pleated Face Mask - repeat on other end, check fit
     
    Non-Pleated Face Mask - slide elastic so that the end is inside the channel
     
    Non-Pleated Face Mask - mask worn with elastic over the ears
     
  23. Filter Pocket: This mask has an optional filter pocket. One option is to insert a folded coffee filter into the pocket.
  24. Non-Pleated Face Mask - pocket for the filter
     
  25. 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.
  26. Non-Pleated Face Mask - alternative elastic using one long piece, pulling through the channel
     
    Non-Pleated Face Mask -elastic pulled through both channels, ends still loose, check fit and tie as before
     
    Non-Pleated Face Mask - mask with long elastic above ear and behind the neck
     
    Non-Pleated Face Mask - finished mask with continuous elastic
     
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  27. 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!
  28. Non-Pleated Face Mask -child's version
     
    Non-Pleated Face Mask - child's mask from the side
     
    Non-Pleated Face Mask - Snoopy themed child's mask
     
  29. The pattern also offered patterns for teens/women and adult men. Here is the one I made for my husband to wear at work.
  30. Non-Pleated Face Mask - adult man's mask on model
     
    Non-Pleated Face Mask - man's mask from the side
     
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