Best Fit Face Mask

Over the weekend I completed something I’m really proud of! Honestly, I worked like a dog because I felt the urgency to share this tutorial with the world. If you happen to follow me on social media, you already know that I created the Best Fit Face Mask. After struggling with several different patterns online I bemoaned the fit on all of them. Not one of the face mask were any I could wear for any length of time. You could say, I consider myself a face mask connoisseur especially because I searched for years to find my more form-fitting and comfortable masks used for carpentry or demolition.

Best Fit Face Mask

As a general contractor and woodworker, I had searched for form-fitting and comfortable masks to protect my lungs from dust and debris and had my favorites. Several didn’t have a good tight fit around the nose, which inevitably meant I was blowing sawdust out my nose at night. A good fitting mask doesn’t allow air to come in next to your nose. For that reason, I knew there were better options than most of the sewing mask patterns I found. After a weekend, I designed this easy sew Best Fit Facemask Tutorial for use by the public and medical professionals trying to protect N95 and surgical masks while also staying safe during the COVID crisis. (These are not a replacement for N95 or surgical masks. These masks are designed to add an additional layer of protection.) Looking for a simple, stylish, and better fitting face mask? Well, I have you covered. Get it? Covered? ;-D

Truth be told, my Mom reminded me I’ve been sewing and perfecting this design for almost forty years! This is me sewing a quilted rainbow vest (remember Punky Brewster?!)

And this was my costume for Future Day in elementary school. It’s a bit crazy that I thought the future was a place where we’d have so much smog we couldn’t breathe clean air. My costume was a mask with an oxygen tank on my back made from an egg carton. Kind of scary how our current day is a place where we fear the air we are breathing.

Thank goodness, we don’t have to wear tin foil covered milk jugs on our heads. I much prefer wearing the Best Fit Face Mask, a more form-fitted cloth mask with adjustable ties around the ears to fit a wider variety of faces (and keep from irritating the ears after wearing for long periods of time). The mask pattern also has an optional filter pocket, should you need the extra protection (although, frankly it gets harder to breathe the more layers you add.)

Here are a few details about the mask:

  • Two Sizes (Medium and Large)
  • Easy to Sew
  • Filter Pocket
  • Adjustable Nose Clip
  • Fitted around nose, chin and cheeks
  • Less Fabric Waste

Are you ready to make your own Best Fit Face Mask?
Click here to be taken to the full instructions with video and downloadable instruction sheet with templates!

One more thing, I share several options for materials, especially because there seems to be a shortage of elastic.


Prefer to purchase a Best Fit Face Mask? This is the link to the database of sellers.

166 replies
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  1. Carrie
    Carrie says:

    This is the best mask pattern! You’re the best!!

    Any advice on how to give dimensions of final masks? Do I give them with it folded in half then multiply by 2? Or do they really need the mask laying flat, pulling taught and giving the measuring along the top for a more accurate width?
    These are very different measurements and I don’t want to be confusing.

    Height I would use it nose to chin with the mask folded in half. Correct?

    Any advice or suggestions??

  2. Susan Debra Havekost
    Susan Debra Havekost says:

    I’m replying to my own comment. I had the fold at the wrong end of the pattern. This design is great and I had wonderful success (finally)
    . It fit all my husband’s needs — nose piece and adjustable elastic. Thank you.

  3. Brenda Richards
    Brenda Richards says:

    I used it for a first grader and a kindergartner and it fit them perfectly. I reduced that pattern by 1/4” for a 3 year old.

  4. Brenda Richards
    Brenda Richards says:

    Had to write you and tell you I have now used this mask pattern to make all sizes including a toddler one I made by reducing child pattern by 1/4”. I have now made one for myself and husband, masks for grown daughters, masks for school children and kindergarten students and now the three year old. Every one of those people has loved this pattern (I tried three others before this one)! Everyone has said they are PERFECT! I use the coffee bag ties for the nose wire. Thank you so, so much for this pattern! Your pattern has made such an impact!

  5. Cathy
    Cathy says:

    Have tried numerous face mask patterns since the start of Covid. This “Best Fit Mask” is BY FAR the best pattern. It is easy to make and fits perfectly.

  6. Susan
    Susan says:

    I could not get this pattern to work for me. When putting front to back I did not have enough fabric on the front to fold down on the sharp vee in the middle of the inside lining. I tried to adjust, but finally gave up. Very disappointing. Anyone else with this problem?

  7. Kellie
    Kellie says:

    I made 3 of these masks back in April, and I love the design and fit. Do you know whether anyone has adapted this pattern to have a clear window for the Deaf community? I plan to make some in response to a request, but I much prefer the comfort and fit of this pattern over the one they’ve suggested.

  8. Jenn
    Jenn says:

    Thank you! I have made several hundred masks based on your design (I modified for a lower cut around the eyes and no folded edges). I have donated over $1000 to COVID relief groups. Thank you for sharing!

  9. Lisa
    Lisa says:

    I love this tutorial and pattern. I’m a new sewer and have cranked out multiple masks thanks to your help. I have discovered the use of pot holder loops as a nice alternative to elastic. Nicer on the ears and my daughter happened to have a large stash!

  10. Alison
    Alison says:

    I like this pattern and have been making them, so far about 15. Please give me advice about how to avoid getting bunched up fabric as I sew around the center where the nosepiece is and also the bottom center. I tend to get a fold of fabric under my stitching there. Any recommendations?

  11. Sue
    Sue says:

    Thanks for providing the templates and instructions for everyone! Could you check the template for the small mask? It appears to be the same size as the medium.

  12. Carol Ziemer
    Carol Ziemer says:

    OMG! I love the bead on the tie threaded in the “u” pattern tie. I have family members who have problems tying behind their heads but don’t like the behind-the-ear ties. Since our governor issued a mandate for face masks going into effect tomorrow, I need to make additional masks and will be trying this new bead idea. This may help get them to wear masks more frequently. Thank you for sharing.

  13. Cara Jones
    Cara Jones says:

    I love this pattern, I have made 7 or 8 masks. I use the coffee filter ties for the nose clip, and the untied hair elastics with pony beads for the ears; but the elastics were too wide, so I sewed them in half lengthwise. And the last one I made I stitched up the whole front instead of just the chin and nose so I have a little more space.

  14. Anne
    Anne says:

    Can not find the pattern and have been searching for two hours and I’m so frustrated. Looking for pattern for best fit face mask.

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