How to make the most comfortable face mask. The origami mask style sits off your face making it the most breathable cloth mask you will wear.
With just a few more steps than my simple sewn mask tutorial this 3D mask is great for when you need more protection or be wearing it for longer periods.
After so long of wearing (and trying) different styles of cloth face masks I have decided this origami face mask is my very favorite. I gave my sister one of these box style masks for Christmas she reported that it was the first time she felt like she could really breathe in a mask while she was in a store!
While I do not make any medical claims to how effective this mask is, and I encourage you to do your own research, in this weird time of mask wearing and after trying a bunch of different styles, this is by far my favorite mask.
My previous sewn face mask pattern is great for making large amounts fast, I prefer this 3D style for more protection and when you have to wear a mask for longer periods like for school or work.
Life looks different than when I sewed my first masks and I feel like this one has the benefit of lots of testing, experience, and seeing how life with masks developed.
Don’t want to make your own? Order one from my Etsy shop.
What We Love About the Origami Mask Pattern
I spent a lot of time developing this pattern. I have to say I LOVE these mask. I’ve been wearing this version for about a month and given some to friends and it is all of our favorites for sure.
- Super comfortable. This makes it a great option when you need to wear a mask for a long period of time.
- Breathable style. Because it sits up off of the face it has room for air flow within.
- Snug fit to account for noses and chins. Unlike other 3D masks I have structured this so that it covers more noses and chins. Chins and noses aren’t the same size and shape so this pattern is not the same on the top and bottom.
- Easy to sew. Even thought it’s got a few more steps that my classic face mask this is still an easy projects even for beginner sewers.
- Reversible. Please don’t reverse it when you wear it but the way this is sewn you can choose which side to display (after washing of course). This is great for making one side with fun holiday fabric but still be able to wear it without your cute nutcrackers marching around in February.
- Great for glass wearers. My glasses don’t fog up because the air seal and fit are so great!
More Face Covering Projects You’ll Love
Before we get to the step by step instructions for the 3D box style origami mask here are some other really helpful mask articles.
- Quick Sewn Mask – classic full coverage fast to make sewn free face mask pattern with lots of helpful hints and tricks about making masks.
- Classic Kid Masks Pattern – more detail on the full coverage speedy masks with lots of tips for making them easy for the little ones to wear.
- Zombie Face Mask – how to make a fun face mask with zombie lips
- Mommy and Me Cat Face Mask – fun simple mask with downloadable design for adding a cute kitty face design.
These tips and tricks and design details can all be used on this origami style mask too!
What You Need to Make a 3D Mask
One thing I love about mask making is that most crafters already have everything they need in their stash. If not the supplies are inexpensive and pretty easy to come by.
Supplies for Making Box Style Face Masks
- Fabric – go for 100% high quality quilting fabric. This has seemed to hold up the best to effective mask testing. Here’s a list of my some of my favorite fabrics!
- Elastic – I adore this super soft style elastic but anything 1/4 or 1/8 inch should work. See this post for all my thoughts on elastic and lots of suggestions for elastic alternatives!
- Thread – I just use whatever I have on hand for most my sewing. For me that’s 100% polyester serger thread that I have held up with one of these to make it work with my sewing machine.
Download Free Origami Mask Pattern
The pattern is available for free download to my newsletter readers. If you are already a subscriber find it on my downloads page remember the password for access is at the bottom of every email. If you’re not a subscriber you can sign up now.
Make sure to print it at 100% scale.
Tools for Making a Box Style Mask
- Sewing Machine – any sewing machine that can do a basic straight stitch will work. This is my favorite machine for beginners and more advance sewist alike.
- Loop Turner – this is one of my very favorite sewing tools. If you do not have one and don’t want to wait to get one you can use a small safety pin instead.
Alternatively you can lay the elastic across the edge of the face mask and fold the casing around the elastic. I don’t prefer this method since it’s too easy to accidentally sew over the elastic then you won’t be able to slide it around but it will do the job if you don’t have a small enough safety pin.
How to Make a 3D Mask
It is easy to make an origami mask. It’s really just a few basic steps.
- Cut the fabric. You’ll need two pieces of fabric they can be the same or different. This pattern is reversible.
- Sewn the fabric together. Sew the fabric right sides together along all edges except the two short sides using a 1/4 seam allowance. Snip the corners and turn right side out and iron flat.
- Fold the top and bottom edges to the center. Fold the top and bottom edges leaving about 1/2 inch space at each edge. The direction you fold it to will be the INSIDE (although it will work fine from either side).
- Make the elastic casing. Fold the ends over 1/4 inch twice. and sew in place. This will leave you with the top and bottom edges folded in, each side folded towards the center and and small triangle of fabric peeking through.
- Sew the top and bottom edges. Fold the bottom flap open in half and pin. Fold the top edge so it is half folded and half hanging over the edge. Take another fold to make two pleats total and pin. The bottom flap gets one pleat/fold the top gets two.
- Test and adjust the fit. I have found for adults this makes a great breathable box. But for my son I need to take the chin part in a bit. I take a small dart in the bottom center of the mask. Doing this makes it so the mask isn’t reversible but it fits him SO much better. If I really wanted a reversible mask with a chin dart you could do the dart step as the very first step, before sewing the two pieces of fabric together.
- Add the elastic. Cut the elastic, the length will vary depending on your particular elastic. I find the super stretchy soft stuff 9 inches is good for most adults and 10 inches is good for the braided elastic. And for kids 8 inches and 9 inches respectively. You still need to adjust how tight you tie the knot for the wear. Thread elastic through the casing using a loop turner and tie a knot to fit.
Cut Out the Mask Pattern and Sew
First cut the fabric. You’ll need two pieces of fabric they can be the same or different. This pattern is reversible.
Sew the fabric right sides together along all edges except the two short sides using a 1/4 seam allowance. Snip the corners and turn right side out and iron flat.
Fold The Origami Mask Shape
Fold the top and bottom edges leaving about 1/2 inch space at each corner edge. Fold the bottom edge first then the top to overlap. The top edge will hang over slightly. Remember you are starting with the lining fabric facing up before you fold. Once you fold you will only see triangles of the lining fabric.
Roll the unfinished side edges under 1/4 inch twice to form a casing. Pin in place and sew in place along the inner edge.
Fold the Origami Mask Shape
Fold the bottom flap open in half and pin in place. Next fold the top edge so it is half folded and half hanging over the edge. Take an additional fold to make two pleats total and pin. The top edge gets two pleats (more nose room) and the bottom edge gets one pleat)
Keep in mind the folds won’t be exactly flat, you’ll have to kind of open up the fabric but you want the edge to line up with the casing. Sew in place along the edge of the casing. So you should now have two parallel lines of sewing.
3D Mask Sizing and Fit Tips
At this point I like to try the mask on and see if anything needs to be adjusted. The pattern is an adult size medium and a child’s size. The adult size fits great on most women and teens I’ve tried it on so far. It is a bit small for my husband would work fine in a pinch. I do plan on making some for him (although he loves my classic mask so I haven’t been in a rush).
Above you can see the adult size on me and my 12 year old niece (who typically wears child sized masks). You can see it’s large on her but besides looking big it’s comfy, stays in place and is super breathable without having any gaps.
The child size 3D mask pattern fits my son perfectly but as is is a bit spacious around his chin. So at this point I like to take a small dart in the bottom center edge of the mask. This makes it the perfect cup around his face. Teddy is almost 7 and I’d say the kid size would be best for most 6-11 year olds.
That being said the other day he needed to wear my mask and it was large on his face but still provided a good closed box and was comfortable on him. I think the larger size just surrounded more of his face so it didn’t need the pleat like I have been adding for the kid size.
Add the Elastic to the Origami Mask
Next you will add the elastic. I highly prefer an 1/8 inch elastic and this is my favorite elastic for masks. It’s so so soft and stretchy but has good bounce back so it will hold the mask in place. And it makes it super comfortable you will not even notice it is there.
I cut the elastic to 9 inches for adult masks and 8 inches for kids but you can play around with what works best for you as it will vary depending on what type of elastic you use.
I like to use a loop turner to pull the elastic through the casing but you can use a saftey pin. Once the elastic is in place tie a knot, try it on and when you get the right size slide the knot around to be hidden and nestled in the casing.
If you don’t have a loop turner or small enoughsafety pin you can add your elastic before you sew your casing by laying it down and folding the casing around the elastic. This is NOT my favorite method because it’s really easy to accidentally catch the elastic in the stitches and then you won’t be able to slide the knot into the casing.
3D Origami Face Mask Tutorial
Instructions
- Cut the fabric. You’ll need two pieces of fabric they can be the same or different. This pattern is reversible.
- Sewn the fabric together. Sew the fabric right sides together along all edges except the two short sides using a 1/4 seam allowance. Snip the corners and turn right side out and iron flat.
- Fold the top and bottom edges to the center. Fold the top and bottom edges leaving about 1/2 inch space at each edge. The direction you fold it to will be the INSIDE (although it will work fine from either side).
- Make the elastic casing. Fold the ends over 1/4 inch twice. and sew in place. This will leave you with the top and bottom edges folded in, each side folded towards the center and and small triangle of fabric peeking through.
- Sew the top and bottom edges. Fold the bottom flap open in half and pin. Fold the top edge so it is half folded and half hanging over the edge. Take another fold to make two pleats total and pin. The bottom flap gets one pleat/fold the top gets two.
- Test and adjust the fit. I have found for adults this makes a great breathable box. But for my son I need to take the chin part in a bit. I take a small dart in the bottom center of the mask. Doing this makes it so the mask isn’t reversible but it fits him SO much better. If I really wanted a reversible mask with a chin dart you could do the dart step as the very first step, before sewing the two pieces of fabric together.
- Add the elastic. Cut the elastic, the length will vary depending on your particular elastic. I find the super stretchy soft stuff 9 inches is good for most adults and 10 inches is good for the braided elastic. And for kids 8 inches and 9 inches respectively. You still need to adjust how tight you tie the knot for the wear. Thread elastic through the casing using a loop turner and tie a knot to fit.
Video
I love this mask so much. I hope you love it as well! It’s by far the most breathable mask I have tried so far.
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Helene Gardel says
What are the inches for the origami mask for an adult. When I tried to print I couldn’t get the whole mask not technical,enough
marissa says
Yes it is half of the mask so that you don’t have to piece multiple papers together like other patterns. You need to cut the fabric on the fold line :)
Naomi Marie Word says
Is there a size recommendation chart available? Chan you provide a guideline? Thank you!
marissa says
There’s a bit about sizing in there but faces surprisingly vary SO much so age is not a great measure. Most women are good with the regular size, tweens and up can wear adult. The kid size is great for about size 5 and up although the adult size will work on younger kids too it will just poof off their face more. I suggest trying a size with scrap fabric and then you can make adjustments ad you need but the way that theses they the sizing is super flexible. It doesn’t need an exact fit. I’m working on smaller and larger sizes too.