How to Sew a Pleated Fabric Mask

Last Updated: April 15, 2020

This a simple tutorial for sewing a comfortable fabric mask for wearing when out in public. Please note that it is not a medical-grade mask for hospital use. This mask has a pocket in the lining so that the wearer can insert a filter, if desired. Remember to remove the filter before washing.

Steps

1
Cut a piece of fabric 10" long x 8" wide. (The fabric should ideally be 100% cotton---quilting fabric works very well for this.)
2
Cut two pieces of fabric 7 1/2 " long x 5 1/2 " wide.
3
Place the two smaller pieces face down and centered on the larger piece. Align the long edges with the top and bottom edges of the larger piece. The smaller pieces will overlap with each other.
4
Sew along the long edges of the top and bottom, using a 1/4 " seam.
5
Fold the smaller pieces back toward the "wrong" side of the larger piece, so that now the "wrong" sides are facing. Top stitch along the top and bottom edges to create a finished edge.
6
Fold up the bottom edge of one of the smaller pieces, about 1/4". Sew. This piece will be the one that lies on top as the pieces overlap.
7
Turn the piece so that the front of the main fabric is facing up. With your thumb and forefinger, "pinch" the fabric to create 3 pleats. Pin each pleat in place as you make it. Press the fabric to make the pleats crisp and to make them easier to sew over.
8
Turn the piece so that the liner fabric is facing up, and sew down over the pleats. Remove pins.
9
Cut the fabric ties. Cut 2 pieces of fabric 1 1/4" wide by 36" long.
10
Sew the fabric ties. With your presser foot up, fold the fabric widthwise twice: first folding the two edges to the center, and then folding that in half. You'll only be able to keep that fold for about an inch without pinning, but carefully slide the folded end of the fabric under your needle, and then lower your presser foot. Sew down the length of the fabric, pausing to fold as you go.
- Do this with both strips of fabric.
11
Place the ties. Place the pleated mask face down, and center a fabric tie down one side, where the main fabric extends past the lining. Fold the main fabric excess over the tie once, and then again.
12
Sew on the ties. Holding the rolled fabric with your fingers, carefully place under your needle, and sew. Repeat, and then do the other side. (It's fine if the tie is sewn down into the fabric).
13
Trim excess thread and press. This will create nice crisp lines.
14
Add a filter, if desired.