How to Sew a 3D Origami Face Mask (Illustrated)

 

This illustrated sewing tutorial will use the Adult S-M size and is slightly different than my original DIY sewing tutorial for making a 3D Origami Face Mask in two ways. This tutorial instructs you to insert ear tie tabs/straps before creating a trifold and to topstitch all the way around once ear tie tabs/straps are inserted. This is my preferred method after sewing hundreds of masks using this design.

Size	Rectangle Dimensions	Corner Crop
Child S-M (5-10 yrs)	7.5” x 6”	1.75”
Child L-XL (11-12 yrs)	8.5” x 6.5”	1.75”
Teen/Adult XS	9.75” x 7”	2”
Adult S-M	10.25” x 7.25”	2.25”
Adult L-XL	10.5” x 8”	2.25”

For a printer-friendly version of my DIY 3D Origami Face Mask Sewing Tutorial click here.

 

Step 1: Place two pieces of pre-cut mask fabric with right sides together. (Click here to see how to create a template to make cutting easier.) Sew using a 1/4" seam allowance along the edges marked in the illustration, leaving the right and left sides open.

Step 2: Notch corners to prepare for turning inside out.

Step 3: Before turning inside out, fold open ends in at 1/4" and iron flat. Repeat on back side. You should have ironed 4 folds. Next, flip inside out and press seams flat.

Step 4: For this step, you can use ribbon (heat treat the ends) or bias tape straps. The straps or tabs will hold the ear ties in place. I cut mine at 2.5" and slide them in 1/4" into the openings. Topstitch around the entire octagon starting on the right side. I use wonder clip to hold my straps in place, but you can also place the straps as you go. Avoid using long stitches for this portion because you want to securely tack the straps into place. 

Step 5: Create a trifold by folding the top and bottom flaps toward the center. You want to make sure the height of the trifold correctly matches the size you are sewing.

Size	TriFold Height
Child S-M (5-10 yrs)	2.5”
Child L-XL (11-12 yrs)	2.5”
Teen/Adult XS	2.75”
Adult S-M	2.75”
Adult L-XL	3.5”

Step 6: Your trifold should resemble the illustration below.

Step 7: You will sew the trifold in place. Use the appropriate spacing from the right and left end depending on the size of the mask you are sewing (see table below). Then use a 1/8" seam on the top and bottom of the rectangle. Remember to backstitch to secure the ends of your broken rectangle.

Size	Trifold Edge Allowance
Child S-M (5-10 yrs)	1”
Child L-XL (11-12 yrs)	1”
Teen/Adult XS	1.25”
Adult S-M	1.25”
Adult L-XL	1.25”

Step 8: Open the flaps outward and fold the ends with straps toward each other. While the mask is folded, pin the flap-folds in place as shown in the illustration. (I prefer to use wonder clips for this step.) You will have four places with pins or clips to hold the folds in place while you sew--this creates the origami design.

Step 9: This part is easiest if you open the mask partially and sew with the interior fabric facing up. The mask will not lay flat at this point because of the origami folds. Tack the origami folds in place as illustrated below.

Step 10: You're almost done! Add ear ties (about 10" for each ear loop if using t-shirt yarn), or create ties that wrap around your head from t-shirt yarn or parachute cord (with a cord lock).

 

 

Sizing Guide

Size	Rectangle Dimensions	Corner Crop	Trifold Height	Trifold Edge Allowance
Child S-M	7.5” x 6”	1.75”	2.5”	1”
Child L-XL	8.5” x 6.5”	1.75”	2.5”	1”
Teen/Adult XS	9.75” x 7”	2”	2.75”	1.25”
Adult S-M	10.25” x 7.25”	2.25”	2.75”	1.25”
Adult L-XL	10.5” x 8”	2.25”	3.5”	1.25”

How to Create a 3D Origami Mask Tracing Template

This tutorial will show you how to create a pattern template to trace "cut" lines onto your fabric. I recommend using a heavy cardstock to create your tracing template. This really simplifies and speeds up the cutting process so you can move on to sewing your masks. I include five sizes: Child S-M, Child L-XL, Teen/Adult XS, Adult S-M, Adult L-XL. 

For the full sewing tutorial, see How to Make a 3D Origami Face Mask (with pictures) and this post with illustrations.

Step 1: Start by cutting out a rectangle according to your desired size.

Size	Rectangle Dimensions
Child S-M (5-11 yrs)	7.5” x 6”
Child L-XL (11-12 yrs)	8.5” x 6.5”
Teen/Adult XS	9.75” x 7”
Adult S-M	10.25” x 7.25”
Adult L-XL	10.5” x 8”

Step 2: To crop the corners, measure the appropriate distance (1.75”, 2”, or 2.25”; see table below) on both sides of the rectangle.

Size	Rectangle Dimensions	Corner Crop
Child S-M (5-11 yrs)	7.5” x 6”	1.75”
Child L-XL (11-12 yrs)	8.5” x 6.5”	1.75”
Teen/Adult XS	9.75” x 7”	2”
Adult S-M	10.25” x 7.25”	2.25”
Adult L-XL	10.5” x 8”	2.25”

 

Step 3: Once the corners are cropped, each template should resemble a rectangular octagon. 

 Step 4: Place your cardstock template on clean, preshrunk, ironed fabric (two layers works better than one). Trace around the template with a pencil or pen. Cut along the marked lines.