How to make a mask cover

1. Materials & tools

Materials (one cover, standard size)

• Fabric (double gauze or silk) — about 25 × 36 cm (for two pieces; scraps are fine)
• Mask elastic — about 24 cm × 2
• Sewing thread

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” → “Mask cover” from the tabs at the top.
2. Enter the size
   Enter the width, the height and the center tuck. Presets cover small, standard and large.
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. Trace the pattern
   Lay the pattern on the wrong side and trace both lines. The center line is the fold.
2. Cut the pieces
   Cut 2 on the fold — a left and a right.
3. Transfer the notches
   Mark where the center curve begins.

4. Sewing

4-1. Sew the center seam

1. Place the two pieces right sides together and sew the curved center edge.
2. Clip the allowance every 1 cm so it does not pull when opened out.
3. Press the allowance open and topstitch either side.

4-2. Finish top and bottom

1. Turn the top and bottom edges under twice, 1 cm each time, and stitch.
2. Gauze stretches easily, so let the machine feed it.

4-3. Make the elastic casings

1. Turn each side edge under by 1 cm, then 1.5 cm, and stitch.
2. Those become the casings.
3. Thread the elastic and try it on before knotting.

✏️ Decide the elastic length with the cover actually on. It sits over a disposable mask, so fitting it on its own makes it too tight. Put the mask on, lay the cover over it, and knot the elastic at the length that feels right.

5. Tips & variations

• Pick what touches the skin: silk and double gauze suit anyone bothered by chafing.
• Keep the mask underneath: this is a cover, not a mask. Always use it over a disposable one.
• Make several: they come out of scraps, so a batch is easy.