Patterns & Instructions
3D Mask
The 3D mask was modified from crowd-sourced designs and optimized by Barb Round. Many masks of this design were made and used in the pandemic. The pattern has been pretested by an independent sewist: it does not require advanced sewing skills. It can be made with a polypropylene middle layer on a domestic sewing machine. This mask is currently being further tested in our research.
3D mask pattern and illustrated instructions
Essex Pleated Mask
Mask pattern updated January 2022
The Essex Pleated mask is a mask that has a proven track record as more than 55,000 masks were sewn by volunteers and donated to members of the community from vulnerable groups by the Windsor Essex Sewing Force during the first three waves of the Covid-19 Pandemic. We found that these cotton masks filtered 40 - 66% of particles, compared with a control medical mask which filtered 55% of particles. This mask is currently being further tested in our research.
Mask Features
The Essex Pleated mask is a 2-ply cotton mask with channels for elastic ear loops or ties. The choice of 2-ply cotton without a filter insert, inner layer or nose wire was made due to resource constraints, availability of materials and meeting needs for community distribution given mask care considerations and safety.
Why doesn’t it have a nosewire? This was a mask designed for community distribution. We observed that nosewires become damaged with washing, and we had received concerns that inclusion of nosewires, even if intact, might lead to a risk of eye damage in some populations whom WESF served. A nosewire can be added if desired. A summary of research on the effects of nosewires on efficacy is here. The masks tested in our research performed in the same range as surgical masks (which have a nosewire), despite not having a nosewire.
Why doesn’t it have polypropylene? Polypropylene can’t be ironed or tumble-dried. Detailed care instructions might not have been followed reliably in all the populations whom WESF served, and might pose problems for some people. The mask-making method required ironing for consistency. Ironing simplifies the method, making it accessible to sewists from a broader range of backgrounds and skill levels, and increasing the speed and efficiency of mask-making. A summary of the reasons to use polypropylene and the caveats is here. The masks tested in our research performed in the same range as surgical masks, despite not having a layer of polypropylene.
The mask is designed to be large with channels on the side. Channels “cinch” to create a custom fit while minimizing the number of sizes needed for widespread community distribution. Channels also allow elastic ear loops to be replaced and/or swapped for ties which provide a more secure fit. This extends the life of the mask as elastic typically wear out long before cotton fabric.
Sizing and Finished Mask Sizes
All sizes of the Essex Pleated Mask are sewn the same way, below are the dimensions and elastic measurements for each size. These dimensions below should be used rather than the measurements shown in the video.
Large (Adult): 9 to 9 ¼” x 4” (fits NIOSH mask sizes for medium, large and extra large)
Medium (Youth & Smaller Adult): 7½”-7 ¾” x 3 ½ ”
Small (Child): 6 to 6 ¼” x 3”
All masks use 10” of elastic on each side of the mask tied loosely so the size can be adjusted. Please do not tuck the knot into the channel so mask users are able to see that the elastic is adjustable. It is preferred to use ties for a more secure fit unless the person is a small child or unable to remove the mask themselves. Click below for sewing instructions (using cut squares and the ironing method for making pleats).
Child/Smaller Essex Pleated Masks
The following videos illustrate how to sew the Essex Pleated Mask and the Updated Method for sewing channels on the Essex Pleated Mask.