How to Easily Make a Comfortable & Breathable Face Mask

Dami Dimension
by Dami Dimension
8 Materials
3 Hours

Don’t you dislike those face masks that stick up right against your nose and mouth making it extra difficult to breathe? Well, I’ve got the perfect solution for you! An easy-to-sew breathable face mask that won’t touch your nose or mouth area, thus making breathing a whole lot easier (and talking, too).

You’re going to love this comfortable face mask, and you can even make a few for yourself or your loved ones. Let’s get started!

Tools and materials:

  • Fabric
  • Cotton fabric
  • Elastic
  • Sewing machine
  • Chalk
  • Fabric clips or pins
  • Thread
  • Measuring tape
Making the breathable face mask pattern

1. Make the DIY face mask pattern

Cut your fabric so that it’s 12 x 12 inches. 

How to make a face mask with fabric

Then, cut out another fabric for the lining. Here, I’m using a lightweight cotton fabric. 

Tip: The size I’m using works great for teens and adults. However, you can adjust the size for kids by taking in more seam allowance. 

How to sew a comfortable face mask

Place the fabric pieces on top of each other, right sides facing, and fold it in half, as shown. 

Folding the fabric to make a DIY face mask

Then, fold it again in half so that it forms a square. 

Measuring a semi-circle on the face mask

2. Cut the fabric

Now, measure 6 inches and use that as a guide to create a semi-circle on the folded square fabric piece. 

Cutting the fabric along the curve

Now, cut along the line accordingly. 

Semi-circle of fabric for the DIY face mask

When you open it up, you should have something like this. 

How to make a breathable face mask

Now, fold the semi-circle upward, and cut the excess pieces. 

How to sew a comfortable face mask

When you open the piece twice, it should look like this. Now, simply cut the pattern in half, so you land up with two pieces. You can now make not one but two face masks!

Breathable face mask design

3. Sew your DIY face mask

Using your measuring tape, measure 1.75 inches from the tip of one side and make a mark. Then, from the same end, measure 1.75 inches on the opposite side of the first mark. 

Marking the DIY face mask

Go ahead, and repeat the same on all the sides. 

Sewing the DIY face mask

Turn your fabric so that the right sides are touching, and then sew along the curved line of each side of the face mask in between the points you just marked. Use a ½ inch seam allowance. 

How to make different sized face masks

For reference, I sewed these two face masks with a different-sized seam allowance. The one closer to the edge will be bigger than the bottom, with a wider seam allowance. This is the trick to make if you want to make different-sized face masks. 

Snipping around the curves

Next, snip around the curved areas. 

Pressing the face masks

Flip your masks right sides out, and give it a good press. This is how your face mask should look like. 

Breathable face mask tutorial

4. Fold in the ends

Neatly and carefully, tuck in the sides of the mask. 

Measuring the length of elastic

5. Cut your elastic 

Cut out two elastics that measure between 8-10 inches in length. The size depends on the mask itself; if you are making a mask for an adult vs. a teen. 

Tip: For kids, you can cut an elastic that measures between 5-8 inches. 

Placing elastic on the ends of the face mask

Now, place each end of the elastic on the sides of the face mask, as shown. 

Marking along the edge of the face mask

6. Make your pleats

On the curved sides of the DIY face mask, measure 4 inches and center it as much as possible. Then mark five lines evenly, as shown. 

Making pleats in the DIY face mask

Next, make the pleats by folding the first line on top of the second. 

Pinning the pleats in place

Continue forming the pleats, using those marks as a guideline. 

Making a breathable face mask

Repeat the same for the other side. 

Tip: Watch my video from 7:08 minutes to see how I make the pleats.

Pinning the elastic to the DIY face mask

7. Stitch the elastic & pleats

Now, stitch the elastic on the side and the pleats across both sides of the face mask. 

Sewing a backstitch across the elastic

Make sure to do a backstitch when you get to the elastic. 

Sewing the DIY face mask together

Do the whole stitch in one go, meaning, pivot where necessary. 

Breathable DIY face mask

Wearing the breathable face mask

How to make a breathable face mask tutorial

Now your comfortable face mask is complete! I love this breathable face mask for so many reasons, and it’s just so agile and easy to wear without making you feel suffocated. Thanks for tuning in, and remember to keep safe and healthy! 

Suggested materials:
  • Fabric
  • Cotton fabric
  • Elastic
See all materials

The author may collect a small share of sales from the links on this page.

Join the conversation