diy Pleated Face Mask w/ Wire Tutorial

Use this tutorial with our Face Mask DIY kits,
or your own fabric and supplies.
Our DIY kits and finished masks are available in our store

Oso and Bean Big Flower Face mask
Oso and Bean dog Face mask
Oso and Bean retro Cowboy Face Mask


diy Pleated Face Mask with Wire

Make your own pleated mask with nose wire. This mask is fully washable, reusable and reversible. Use a fun coordinating fabric to change it up. If we need to wear masks, we might as well have masks we like.

Included in the Oso and Bean DIY Mask kit (or use your own supplies):
2 – 6″x9″ pre-cut, pre-shrunk coordinating cotton fabric
2 – 6 1/2″ – 7″ white elastic, 1/4″ wide
1 – 3 1/2″ aluminum wire for  nose

You need:
-Sewing machine with coordinating OR Needle and Thread for hand sewing
-Sewing Pins or Fabric clips
-Dull pencil or chopstick to push out corners of sewn mask
-Hot Iron

1Download pattern and stitching guide. Be sure to  print your pattern at 100%. You can use this pattern to make masks using your own fabric and supplies. Trim pattern to size for easier use

2– Pin elastic  to top and bottom edges of short sides of one piece of fabric, on the “right” or outer side of fabric.

3– Place second piece of fabric with the right/outside facing the right/outside of pinned fabric. Elastic should be sandwiched between.

4 – Starting approx. 1 ½” from bottom right corner sew ¼” seam around entire mask. Leave approx. 2” opening on right short side. Be sure to anchor the beginning and end or your seam.

5 – Turn mask right side out through opening and press flat. Be sure to tuck in open edge seam and iron flat. Use a dull pencil to push corners out.

6 – Using mask pattern guide, pin or chalk to mark the placement and size of the top-stitching for nose wire channel. With your needle down (sewing machine) begin top-stitching the channel on  upper right corner. Sew three sides and with needled down, raise your presser foot.

Through the open edge insert nose wire into top-stitched channel (using nose wire provided in kit or make your own, per video tutorial, below)

7 – When wire is fully inserted, lower the presser foot, turn mask and sew final end of top-stitch channel to close.

8 – Hand-pleat THREE pleats on each end of mask (no need to sew open side, unless you wish to add decorative top stitching) Pin pleats on each end in place.

IMPORTANT: The size and tightness of your pleats determine the fit of your mask. NOT the length of the elastic. See bottom for notes on sizing with pleats.

9 – Top-stitch the  each ends of the pleats near the elastic.

YAY! You are done.
When you first wear your mask, gently push nose wire over the bridge of your nose.
You can use the reverse side of your mask without needing to re-bend your wire.


Tips & Tricks

  • If you use your own supplies be sure to use only 100% cotton. Tightly woven cottons, like quilting fabric is breathable and comfy while offering good protection. Take care using T-shirt fabric. What you gain in comfort, you may lose in breathability.
  • Use at least 2 pieces of fabric. You will get more use if you use coordinating fabrics so your mask is reversible…and you will get less bored with your mask.
  • When sewing on a machine, it’s recommended to use your machine’s “needle down” feature, if it has one. This will make for more accurate corners and turns.
  • When turning fabric inside out:
          -cut the corners of your seams off, being careful not to cut your seam. This will make turning corners easier and neater.
         -Use a dull pencil to help push the corners of your mask out.
  • Use 22 or 20 gauge floral wire or non-tarnish craft wire if you don’t have aluminum nose wire: cute wire to approx. 3 ½”, and bend ends into small loops to keep wire from poking out of mask.


Fitting Your Mask

The size of the pleats determines the fit of this particular mask. The tighter you pleat, the smaller the mask end, the smaller the diameter of the elastic loop.

Play around with pleating and fit by sewing / basting the pleats or carefully pinning and trying on the mask. Adjust pleats until you get a comfortable, but slightly snug fit. Elastic will relax with use and washing.


3-Part Video Tutorial

For more in-depth info and tips: