Origami (Beta) - Fitted Mask

Printable Sewing Instructions (4 Pages)
Paper Folding Instructions & Pattern (2 Pages)
Instructions with Schematics (10 Pages)
Photo Tutorial (16 pages)

The “MakerMask: Origami (Beta)” is designed as a stand-alone fitted mask with a number of features to improve accessibility. This mask is constructed without any seams in the central mask area and creates a 3-D shape around the face that gives extra space around the mouth and nose.

Mask Features:

Single latex-free silicone headband improves fit and accessibility
Large breathable surface area!
Compatible with Hearing Aids and Ear Buds
Washable
Available in multiple sizes
Construction Time: 10 – 20 minutes

Technique:

This mask is a sewn mask constructed from a square of fabric material (two or three layers) which is transformed into a 3-dimensional fitted mask by a series of pleats and origami folds. These folds are stitched into place, creating a padded trim around the circumference of the mask, which both improves the seal to the face and increases the comfort of the mask. Before you get started, consider practicing the origami folding with a piece of paper.

Click here for a Paper Folding Instructions and Pattern or Click here for a video of the paper folding

Origami Mask Instructions (Beta Version 0.2)

Materials & Equipment
Materials Two or Three Squares of Fabric – 9” x 9” each (spunbond nonwoven polypropylene [NWPP] fabric preferred for outermost layer(s), skin contacting layer may be NWPP or cotton). One Flexible Nose Piece (coffee tin ties preferred – 5.5″ x 0.25″) One Head Band/Strap: (e.g., 9” x ¼” silicone kitchen band cut open to provide an 18” strip) Headband attachment loops (Small loops can be made out of 2-inch strips of grosgrain ribbon or other fabric) Equipment: Sewing machine (size 16 needle/jeans needle), scissors, ruler, paperclips or similar.
Sew Layers Together
Step 1: Sew Layers Together A. Place all of the layers of fabric directly on top of each other, with the edges aligned. B. Sew the layers together along each of the 4 sides leaving a 2” section unsewn ( ¼” seam allowances used throughout). C. Trim excess fabric, especially at the corners and then turn the square inside out through the 2” unsewn section.
Add Nose Piece & Attachment Loops
Step 2: Add Flexible Nose Piece A. Turn Down the top ¾” of fabric. B. Place the flexible nose bridge under the nose flap, so that it is centered around the mid-line of the mask.
Step 3: Add Attachment Loops and Sew The Fold Down A. Tuck attachment loops under fold. B. Sew the fold down, securing the nose piece and attachment loops in place. (For added durability reinforce the stitching on the loops using a “box X” stitch or similar)
Add Pleats
Step 4: Add Two “Waterfall Pleats” A. Add two pleats, each ¾” wide and ¾” deep Measure ¾” down from the bottom of the fold for the nose piece. To create a pleat ¾” deep, the fabric should be folded so this point is held to the point 1 ½” down. Repeat for the second ¾” pleat. B. Use clips (or basting stitches) to hold pleats in place
Add Origami Folds (see video for details)
Step 5: Fold The Bottom 2 ½” Under A. Fold the bottom 2 ½” under (to the back) B. Turn the mask over
Step 6: Fold ¾” Down A. Fold ¾” of the back down to create “trim”.
Step 7: Create 3D Mask Shape A. Fold the bottom corner of one of the sides up to create a right triangle that intersects with the top edge of the “trim”. B. Tuck the top edge of the triangle (step 7A) under the ¾” flap created in step 6A. Hold the flap in place over the triangle with a clip (yellow in photo). C. Repeat for the other side.
Step 8: Sew The Final Seam A. Expand mask into 3D shape. B. Sew the “trim” in place, securing the trim and all the pleats in place. This trim will create the seal to the face along the cheeks and chin line. Extend the stitch line over the the attachment loops to reinforce the stitching
Attach Headband
Step 9: Attach Headband A. Thread silicone band through the attachment loops, adjust to desired length (~18 inches) and tie knots in the ends to hold in place. To ensure that the band is held securely into place, loop the band through the attachment loop before tying (see photos).
Step 10: Expand Pleats and Enjoy the MakerMask: Origami!

Quick Reference Guides for 3 Different Origami Mask Sizes

Click the individual images below to enlarge them or click here to download the pdf.

Slide with photos and instructions for the sewing and origami folds of the MakerMask: Origami - Adult-sized masks (pink masks with floral interior)

Slide with photos and instructions for the MakerMask: Origami Small/Kids (blue mask with white interior)

Slide with photos and instructions for the Extra Small MakerMask: Origami (all masks are green outside and white interior)

Additional Pattern Variations

Click on the gray boxes below for additional information about pattern variations for this origami mask.

For Small/Kids Masks

For Extra Large Mask: Start with a 10″ x 10″ square and use 3/4″ pleats. This variant is popular with people with beards.

For Small/Kids Mask: Start with an 8” x 8” square. Use ½” pleats instead of ¾” pleats. NOTE: Coffee tin nose ties may be too large/stiff for children’s mask. See notes in the cheat sheet for the “Extra Small” for improving fit to the face in absence of nose bridge. For “extra small” smaller masks consider starting with a 7” x 7” square and two layers of lighter weight material.

Size Adjustments

Size Adjustments: The length of the silicone ties can also be shifted to improve the fit.

To create a roomier mask and/or to decrease the number of layers to sew through for thicker materials, consider using one pleat instead of two (Step 3); otherwise follow directions as written.

The size of the mask can also be adjusted by using ½” pleats instead of ¾” pleats or changing the fold at Step 4 from folding 2 ½” back to folding 2 ¼” or 2” back instead. Other folding variations include changing the depth and angle of the pouch-like breathing area by changing the amount of material folded over in Step 4, and altering the angles of the folds (steps 4 and 5).

Layers

Mask Layers:

Standard layering combinations include 3 layers per the WHO guidance on masks. For increased particle filtration, additional layers may be added as long as the mask remains breathable. For increased comfort (decreased filtration), especially during summer months, some people may decrease the layering to two layers, which increases the duration of time that masks can be comfortably worn correctly.

Standard – 3 Layers. Either 3 Layers of spunbond nonwoven polypropylene (NWPP) OR 3 Layers (e.g., 2 Layers of spunbond NWPP as the outermost layers and one layer of cotton as the innermost layer – closest to the face)
Summer-weight – 2 Layers (less filtration, higher breathability). Either 2 layers of spunbond NWPP (e.g., one heavyweight [80 – 100 GSM] and one lightweight [40 – 50 GSM]) OR 2 layers: an outermost layer of spunbond NWPP (80 – 100 GSM) and an innermost layer (closest to the face) of cotton.

No-Sew Window Mask

The basic pattern for the MakerMask: Origami was adapted to accommodate a window, and is illustrated (both instructions and video) in the “MakerMask: Expression”.

Ear Loop Adaptation

The MakerMask: Origami can be adapted for use with ear loops (in cases where headbands/straps are not appropriate) by adding a second pair of attachment loops to the mask. These attachment loops should be located on the trim of the mask below the bulk of the second pleat (approximately 2.5″ below the top set of attachment loops). The preferred ear loops configuration includes an embedded lanyard, which allows the ear loop tension and fit to be adjusted with a single cinching element either behind the head, or under the chin. The preferred material for the ear loops/lanyard is a single strip of T-Shirt material (100% cotton jersey knit). See ‘cheat sheet’ below for details.

— The video below shows the fit of the mask, as well as doffing the mask with one hand without touching the central mask area (Note, there is no audio associated with this video). —

Mask Features:

Technique:

Origami Mask Instructions (Beta Version 0.2)

Materials & Equipment

Materials

Two or Three Squares of Fabric – 9” x 9” each (spunbond nonwoven polypropylene [NWPP] fabric preferred for outermost layer(s), skin contacting layer may be NWPP or cotton).

One Flexible Nose Piece (coffee tin ties preferred – 5.5″ x 0.25″)

One Head Band/Strap: (e.g., 9” x ¼” silicone kitchen band cut open to provide an 18” strip)

Headband attachment loops (Small loops can be made out of 2-inch strips of grosgrain ribbon or other fabric)

Equipment:

Sewing machine (size 16 needle/jeans needle), scissors, ruler, paperclips or similar.

Sew Layers Together

Step 1: Sew Layers Together

A. Place all of the layers of fabric directly on top of each other, with the edges aligned.

B. Sew the layers together along each of the 4 sides leaving a 2” section unsewn ( ¼” seam allowances used throughout).

C. Trim excess fabric, especially at the corners and then turn the square inside out through the 2” unsewn section.

Add Nose Piece & Attachment Loops

Step 2: Add Flexible Nose Piece

A. Turn Down the top ¾” of fabric.

B. Place the flexible nose bridge under the nose flap, so that it is centered around the mid-line of the mask.

Step 3: Add Attachment Loops and Sew The Fold Down

A. Tuck attachment loops under fold.

B. Sew the fold down, securing the nose piece and attachment loops in place. (For added durability reinforce the stitching on the loops using a “box X” stitch or similar)

Add Pleats

Step 4: Add Two “Waterfall Pleats”

A. Add two pleats, each ¾” wide and ¾” deep

Measure ¾” down from the bottom of the fold for the nose piece. To create a pleat ¾” deep, the fabric should be folded so this point is held to the point 1 ½” down. Repeat for the second ¾” pleat.

B. Use clips (or basting stitches) to hold pleats in place

Add Origami Folds (see video for details)

Step 5: Fold The Bottom 2 ½” Under

A. Fold the bottom 2 ½” under (to the back)

B. Turn the mask over

Step 6: Fold ¾” Down

A. Fold ¾” of the back down to create “trim”.

Step 7: Create 3D Mask Shape

A. Fold the bottom corner of one of the sides up to create a right triangle that intersects with the top edge of the “trim”.

B. Tuck the top edge of the triangle (step 7A) under the ¾” flap created in step 6A. Hold the flap in place over the triangle with a clip (yellow in photo).

C. Repeat for the other side.

Step 8: Sew The Final Seam

A. Expand mask into 3D shape.

B. Sew the “trim” in place, securing the trim and all the pleats in place. This trim will create the seal to the face along the cheeks and chin line. Extend the stitch line over the the attachment loops to reinforce the stitching

Attach Headband

Step 9: Attach Headband

A. Thread silicone band through the attachment loops, adjust to desired length (~18 inches) and tie knots in the ends to hold in place.

To ensure that the band is held securely into place, loop the band through the attachment loop before tying (see photos).

Step 10: Expand Pleats and Enjoy the MakerMask: Origami!

Quick Reference Guides for 3 Different Origami Mask Sizes

Additional Pattern Variations

Mask Layers:

Ear Loop Adaptation