How to make a fitted mask (2-piece)

1. Materials & tools

Materials (one mask)

• Outer fabric (double gauze, cotton) — about 25 cm square
• Lining (gauze or cotton) — the same
• Nose wire (aluminium or craft wire) — about 10 cm
• Flat mask elastic (3–4 mm) — about 30–35 cm × 2

Tools

• Sewing machine (or needle and thread)
• Fabric marker or pencil
• Ruler and scissors
• Iron
• Pins or clips

2. Make the pattern (auto-generated in Katagami)

With the Katagami pattern tool, you just enter the finished size and it drafts a seam-allowance-included pattern, tiled to print at actual size on Letter or A4.

1. Open the tool
   Open the pattern tool and choose “Accessories” → “Fitted mask (2-piece)” from the tabs at the top.
2. Enter the size
   Enter the face width, nose-to-chin length and nose depth. Three sizes.
3. Set the seam allowance
   Use the slider at the bottom (beginners: 1.0–1.5 cm / about 3/8–5/8 in).
4. Print
   Press “Print (actual size)”, then in the print dialog set Scale = 100% and turn “Fit to page” OFF. Check the 50 mm calibration box on the first guide sheet with a ruler.

3. Cutting the fabric

1. Cut the upper piece
   Place the center edge on the fold and cut one outer and one lining (2 total).
2. Cut the lower piece
   The same way: one outer and one lining (2 total).
3. Finish the edges
   Zigzag the edges so thin fabric doesn't fray.

4. Sewing

4-1. Join the upper and lower on the center curve

1. Sew the outer upper and lower pieces right sides together along the curved center (nose-to-mouth) line.
2. Clip the curve (about every 5 mm) and press open. Do the same for the lining.

4-2. Sew outer and lining together

1. Place outer and lining right sides together and sew the two sides and the top (nose) edge, leaving a 5–6 cm gap at the bottom (chin).
2. Clip the corners, turn right side out and slip-stitch the gap; press.

4-3. Add the nose wire

1. Make a small pocket near the top seam and insert the nose wire (or slip it into a small opening in the top seam), then close it.

4-4. Add the elastic

1. Make small loops at the sides (folded fabric or bias tape), or fold the side allowances to take the elastic.
2. Thread the elastic, fit it over your ears and tie or stitch the ends.

5. Tips & variations

• Better fit: the nose wire seals the top for glasses-wearers.
• Filter pocket: leave the lining seam partly open to add a filter.
• Adjustable: cord stoppers on the elastic dial in the fit.