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03.30

How to Sew a Face Mask with Filter Pocket (NO ELASTIC!)

Welcome to See Kate Sew! If you’re new here, sign up for my email newsletter for access to free patterns, tutorials and all the latest sewing news! Tour my sewing room HERE!

Last week I shared 3 ways to make a face mask and where to donate them. I’m so happy that so many sewers are coming together to fill this need! Today I’m sharing how to sew a face mask with filter pocket for hospitals wanting a more protective mask. These have a few great features including a pocket on the back to slip a disposable filter into, cotton ties without elastic to withstand harsh sanitation processes and two different fabrics to distinguish the front from the back! Face Mask with Filter Pocket Pattern

This face mask is my new favorite to make. The back requires 2 pieces to create the pocket, so it’s actually a 3-layer mask when you’re all done! It feels like a high quality face mask and I hope it will offer more protection.

Face Mask with Filter Pocket Pattern

The ties are made from fabric, too. You can use premade bias tape or make your own binding with this tutorial. Binding is easy to make and you can’t run out of it!

This mask has NO elastic so that it can withstand high heat in the sanitizing process. You can download the pattern pieces for face mask by clicking on the pattern button below.

Face Mask with Filter Pattern Download

The filter pocket is made with two overlapping folded pieces of fabric! See the pocket open above and closed below:

Sewing face masks is a perfect beginner project! If you are wanting to get started sewing, check out my list of best sewing machines for beginners!

Face Mask with Filter Pocket Pattern

Filter Pocket Face Mask Materials

  • High quality 100% cotton fabric
  • Contrast fabric for the back – Since healthcare workers have to take these on and off, they need to be able to remember which side goes towards their face.
  • 1/2″ binding or bias tape
Face Mask with Filter Pocket Pattern

Instructions for Face Mask with Filter Pocket

Click below to download a PDF version of these instructions! It prints on 2 pages so you can have it by your side when you sew!

Printable Face Mask Instructions

Use a 1/4″ seam allowance.

First cut out one front and two back pieces with the pattern pieces provided. The front piece measures 9″ by 7″ and the back pieces are both 9″ by 8″.

For the binding cut two strips of fabric 2″ by 44″. 44″ is the length of the fabric from selvage to selvage so you can easily cut strips from yardage.How to Sew a Face Mask with Filter Pocket (NO ELASTIC!)

Fold the larger back pieces in half lengthwise and press. You will have two pieces that are 9″ by 4″.

Face Mask with Filter Pocket Pattern No Elastic

Pin the folded back pieces to the right side of the front piece. Match up the raw edges at the top and bottom of the mask. The fold edge of the back pieces will overlap about 1″, creating a pocket. Sew the side seams with a 1/4″ seam allowance. Do not sew the top and bottom. Turn right side out and press.

How to Sew a Face Mask with Filter Pocket (NO ELASTIC!)
Face Mask with Filter Pocket Pattern

Fold the long edges of the binding over so they almost meet in the middle. Press. Fold in half again to complete the double-folded binding. Pin mask into the middle of the binding.

Face Mask with Filter Pocket Pattern
Face Mask with Filter Pocket Pattern

Sew close to the open edge of the binding, sandwiching the mask inside. Fold under the binding edges and catch in the same seam. Backstitch. Complete at top and bottom of the mask.

Create 3 pleats about 1/2″ each, all facing downward. Pin and stitch well.

Face Mask with Filter Pocket Pattern

And you’re done!

Face Mask with Filter Pocket Pattern

More projects to help others!

Be sure to check out 3 more ways to make a face mask(and where to donate!) for neighbors and friends and find more ways to Sew4Good here!

Also, make some masks for your children with this Kid Face Mask Tutorial in 2 sizes!

Printable Face Mask Pattern
Printable Face Mask Pattern
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79 Comments | Accessories, Free Patterns, Sew4Good

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Reader Interactions

79 Comments

  1. Sarah

    03/30 at 8:29 AM

    I love the new face mask pattern, thank you.
    Please may I ask that if possible, could you make the instructions easier to follow with a pdf format as with the mask pattern please. As I find it hard to follow the instructions whilst trying to sew the mask.

    Many Thanks

  2. Iantha

    03/30 at 3:12 PM

    This is an interesting concept, but what kind of filter do you put in it?

    • Annie B

      04/04 at 8:46 AM

      Some people use just a coffee filter

      • Cindy

        04/16 at 2:26 PM

        You can also use Oly-Fun non woven fabric. Just cut out the piece you need for the pocket.

      • Elizabeth G.

        04/23 at 10:42 PM

        I saw a tv news program suggest folded over paper towel.

    • Margie

      04/05 at 5:26 PM

      Just last week an independent company did testing, and they found that the blue woven shop towels that come in a roll like paper towel work very well. Google DIY face mask w/ disposable filter and go to the April 2 article at Business Insider. I don’t know how to put a link into this comment- sorry.

      • Kathy

        04/09 at 5:54 PM

        I have seen masks with bias tape ties across long sides and also some on the ties on the short sides. Which is better?

      • Janet Duley

        04/21 at 9:52 AM

        I bought some and have been using them. The first time I looked, I tried an auto parts store, and online. I found them, by fluke, at a good price in an Ace Hardware store.

    • Chrissy

      04/10 at 9:45 AM

      You can also you a shop vac filter.

  3. Becki

    03/31 at 11:18 AM

    Question – I’ve made the masks without the filter pocket and now need to make ones with pocket – I’m a bit confused looking at the directions – I know to pleat the front but are you also pleating the back? How would you do that when they are already sewn together? I’m going to go try a few things – but would appreciate how you did that.

    • Maryann Mehegan

      04/24 at 11:19 AM

      You only sew sides. The back has the pleats you are making automatically. The pleats will open up significantly when on, since only sides are sewn.

  4. Barbara

    03/31 at 9:27 PM

    Thank you for sharing this pattern! I like the simplicity, the filter pocket, and the use of ties so that it can be laundered frequently. I am guessing that someone at home caring for an ill person would need a decent supply and want to change frequently. My question is if it matters if the ties are put on before or after the pin tucks are sewn down? Thank you again.

    • Marie P

      04/06 at 3:59 PM

      Hi, Thank you for you post. Just a note.
      My local hospital needs all cotton because the sanitation process melts synthetic fabrics.

      Yes, I used bias tape on my mask. Laundered at home.

      Please make masks with what you have. There is a great need.

    • Pamela J

      04/06 at 7:19 PM

      I added a 3 inch piece of a pipe cleaner (chenille stick) in the top binding in the middle to help it seal better around the nose. For a filter, I will use either felt, coffee filter or unscented dryer sheet.

      • Donna DeLoach

        04/07 at 10:12 PM

        Pamela J, I did the same thing. I put a 5″ pipe cleaner and the top binding. The guy in my neighborhood that works at a hospital said they really need the nose form. It worked like a charm.

      • Claire

        04/19 at 10:59 AM

        Unscented dryer sheet is too loosely fiberized to have any filtration value.

      • Jeanne

        04/19 at 2:13 PM

        Dryer sheet not safe due to chemicals they use!

    • Kate

      04/07 at 5:09 PM

      Nope, you can do that part in any order!

  5. Jayne Walker

    04/01 at 8:12 AM

    I have printed the pattern for pocket facemask. On the instructions it says cut 1 front & 2 back. The measurements say 9×8 back & 9×7 front. I’ve measured the templates & they are the wrong way round. It should be bigger one x2 for back & smaller one for front.

    Can you check & advise please before I cut the back.

    Thanks
    Jayne

    • Sarah

      04/04 at 10:48 AM

      Fold the 2 backs “hotdog” style. Then they are 9” wide and 4 long. 8 total When they over lap one inch, they fit on the front piece which is 9 x 7.

    • Linda

      04/04 at 12:53 PM

      It works out as printed. Then the back pieces are folded, they are 9 x 4. The front piece is 9 x 7. When you sew them together, the folded edges of the back are supposed to overlap by an inch.

    • Amy

      04/04 at 7:21 PM

      I only just figured this out… after cutting thee wrong dimensions for about 30 masks. :(

    • Judy

      04/06 at 4:41 PM

      You would need two for the back in order to gain access to the inside in order to put in a filter.

    • Laurel LaBorde

      04/06 at 5:48 PM

      I have made many…..the instructions are correct…..the sizes are correct as written…..
      They turn out perfect.

    • Lisa

      04/16 at 7:21 PM

      worked perfectly as instructed. made 2 in 30 minutes. so easy

  6. Juli

    04/01 at 11:33 AM

    Fantastic thank you. This is probably a stupid question but are the filters easy to purchase?

    • Mari Noonan

      04/04 at 11:17 AM

      What do you use for filters

    • Bill

      04/05 at 5:38 PM

      Been wondering the same thing, and I can’t seem to find anywhere what filters people are actually using. I don’t understand why everyone is posting these instructionals without giving instructions on what filters they’re actually using and where to find!

      • VICKI JOHNSON

        04/08 at 11:28 PM

        You can use coffee filters, but blue shop towels on a roll work best or you can but a furnace filter that says it filters out viruses.

    • Nancy Denberg

      04/06 at 1:50 PM

      Fabulous thanks so much! What type of filters are being used for inside?

    • Maria

      04/08 at 8:23 PM

      I am using micron vacuum filter bags, unused, of course. I cut it open flat, cut to size (approximately 6 by 7 1/2 inches), separate the filter from paper and place carefully into mask.

      • wimora

        04/19 at 10:05 PM

        Filters… please make sure the Vacuum or HVAC filters being used do not contain fiberglass fibers. Some manufacturers use in the making them.
        Help support and cause no harm… :)

  7. Sally Greenbeck

    04/01 at 1:34 PM

    Thank you so much for the instructions and video. Your directions are clear, and easy to follow; much easier than a number of other sites.

  8. LINDA SCHRAMM

    04/01 at 3:22 PM

    I am so glad I found this pattern. However when I went to print, I got a bunch of print over the picturial instructions. Could you email me the pattern instructions?

    Thank you,

    • Jen

      04/05 at 1:09 PM

      This pattern is very easy to follow…until it’s time to stitch the pleats. With all of these layers of fabric, it’s impossible to stitch through. What’s the secret? Simply pinning and stitching is not doing the trick.

  9. Lisa

    04/01 at 4:07 PM

    I just keep getting a circle going round and round when I try to download the pattern for this face mask :(

    • Amy

      04/04 at 3:21 PM

      That is an issue with your device or network, not the pattern. Just FYI.

  10. Kristine

    04/01 at 8:25 PM

    What type of filters can be put in these ?

    • Sue

      04/03 at 12:41 AM

      Others have asked this question but I can’t find the answer. What are people using as the filter? Pieces of vacuum cleaner bags? T shirt material? Paper towel? Other suggestions?

      • Taran

        04/08 at 10:51 PM

        Blue shop towels as people have said. Or there is a significant improvement in function with even coffee filter or folded paper towel.

        Don’t use vacuum cleaner bags- many of the filtering ones are made of materials that could be harmful when cut and put near the mouth, like fiberglass.

    • Dave

      04/05 at 12:12 PM

      Consider a cut-out made from a blue shop towel. Seems to be getting good reviews as a filter and easy to find

    • Kathleen

      04/08 at 10:11 PM

      coffee filters

  11. Cyrus

    04/02 at 5:39 AM

    Thank you for this, round elastic been giving me a hard time.

  12. Shannon Konyndyk

    04/02 at 12:57 PM

    Hi, I am going to make this pattern, but I was curious about pleating the front and back together, does that make it difficult to get the filter in after the fact? Thank you!

  13. Nelle

    04/02 at 2:07 PM

    Fantastic pattern with very clear directions.

    What do you suggest using for the insert filter?

    • Marge

      04/03 at 3:50 PM

      I plan to use a paper towel for my filter.

    • Theresa

      04/05 at 8:24 AM

      I cut up a high quality furnace filter that filters out dust, mold, virus, etc.

    • Kate

      04/08 at 10:14 PM

      You can use coffee filters.

  14. Judy Moore

    04/02 at 3:56 PM

    I would like to able to print the face mask pattern, please.

  15. Sandee Kustermann

    04/02 at 8:01 PM

    Best pattern out there!

  16. Lynn L Sowinski

    04/03 at 11:25 AM

    Do you have size specifications for a child’s mask? Thanks for this invaluable help!

    • Jeanine Preboski

      04/14 at 2:14 PM

      child’s mask using elastic

  17. Susie

    04/03 at 3:59 PM

    Use coffee filters for the filter

  18. Tara Liddicoat

    04/03 at 6:16 PM

    Thanks, going to give this a try this weekend. Do you have a recommended adjustment for a child-sized mask?

  19. Dianne

    04/03 at 8:37 PM

    Would love to get the download for the filter pocket face mask, but the link to submit the email is not working. Any suggestions?

    Thank you!

  20. Jody

    04/04 at 12:02 PM

    Thank you for the pattern! I am using it, but I did copy the more detailed instructions into a Word document, edited the pics down and now have a very usable piece to sit on the machine beside me as I sew! I am making them and donating them as fast as I can. I am also starting to use some single cotton knit material I had in my stash as ties rather than the binding material which takes long time to sew. We will see how it goes. Innovation innovation, sewers is thy name!

  21. MJ

    04/04 at 2:21 PM

    I have read about a group in LA that has been testing materials for use in masks. The best they have found is blue shop towels. – here is a link to the story: https://apple.news/ANWRjyL33RVWiS65W4ME2MA

  22. Bekah

    04/04 at 3:19 PM

    Do you have a recommendation for fabric size for a childrens mask?

  23. Anna

    04/04 at 6:11 PM

    Where can I find a filter to go in these?

  24. SKj

    04/04 at 6:26 PM

    There is no problem boiling / hot washing elastics. They are approved for that. :-)

  25. Cathy Grahame

    04/04 at 7:30 PM

    Thank you so much for this pattern. I am confused regarding the pleats as well, as other posters have stated. The instructions say to attach front and back and attach bias tape, then add pleats. The pictures only show the front pleated which isn’t possible if the front and back are already connected. Please help us understand your instructions. It would be nice if you had a PDF that had clear instructions. Thanks so much.

  26. Rebecca

    04/04 at 9:50 PM

    I couldn’t find elastic anywhere but luckily stumbled across Xpand, which makes elastic laces at http://www.xpandlaces.com

  27. Dr. Ann from AK

    04/04 at 9:53 PM

    Being a health professional (ER physician), I so greatly appreciate this effort of yours. Everyone! Cross your fingers!

  28. Theresa

    04/04 at 10:22 PM

    Love the pattern just don’t understand how to put the pleats in. Can you help me?

  29. Cheryl

    04/04 at 10:57 PM

    What type of Filters are recommended to purchase for these? Please and Thank you

  30. Jaime

    04/05 at 1:22 PM

    The inventor of the N95 masks suggests using blue shop towels as filters.

    What is the total yardage needed per mask?

  31. Jess

    04/05 at 1:51 PM

    Any chance you would mind making a YouTube video for those us that are visual learners? I would be so grateful.

  32. Cynthia

    04/06 at 8:28 AM

    Thank you for the pattern. Made several of these now for my daughter, a nurse, to wear with her N95 respirator.

  33. Heidi

    04/06 at 3:03 PM

    I have made several of these already – fairly easy to follow. I made a few changes, though. I didn’t have fabric long enough to make the straps, so I used ribbon. I also added a piece of wire along the top when I sewed in the ribbon to go over my nose and under my glasses. Tighter fit and won’t steam up my glasses. Finally, for the filter, I have been told to use paper towels or vacuum bag filter.
    Thank you!

  34. Pat L Johns

    04/07 at 10:23 AM

    I cannot print this pattern like you said on two sheets… can you email it to me/ ty..

  35. Nick

    04/07 at 10:37 AM

    I’d like to make this. But I do wonder can this be used for a child or is there another measurement you would recommend?

  36. Carlisle Harper

    04/07 at 1:28 PM

    Hi! I’ve loved working with this pattern. You are great at explaining things clearly. Thank you! Do you happen to have the same mask pattern but for younger children, say ages 8/9 years old?

    Carlisle

  37. Lib

    04/11 at 10:31 PM

    Re:filters. I read that some vacuum and hepa filters have fiberglass in them. Please check your filter before you use it. I would think you could google the exact contents.

  38. Jen

    04/12 at 7:10 PM

    I assume the pleats only go on the front piece?

  39. KATHY ALLAIRE

    04/14 at 10:41 PM

    Thank you! My friend is a nurse and is allergic to latex. This will be great!

  40. Tracey

    04/19 at 12:53 PM

    I fine it easier to sew the ties on before pinning the folds/pin tucks….the fabric stays straight/flat. Is harder once the folds are pinned.
    Also made my own ties from same fabric ..2″ strips, 40″ long..fold longwise and iron then sew…fold longwise again and iron…and they’re ready to affix to the mask.

  41. Holly

    04/20 at 4:47 PM

    Thank you for this pattern! I wear hearing aids and glasses. There’s just too much behind my ears. This pattern allows me to wear a mask and not interfere with anything else.

  42. Nancy Tansy

    04/20 at 9:02 PM

    I found this mask very easy to make after watching Kate’s video above. Very helpful! (The pleats are on the front and back and sewn at the same time. Just follow the directions.) However, when I tried on my finished mask, there were significant gaps at the sides of my face. Any suggestions on how to remedy this? Thanks so much, and good luck everyone!

  43. Carol Bailey

    04/26 at 11:27 AM

    Instead of ties how could I use elastic. I love this as it makes a heavier mask.

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