Domed "duck bill" style face mask


Variation on the Ragmask.  

I printed out the pattern from this site but changed some of the steps:  https://ragmask.com

I used two layers of quilters cotton, a layer of unwoven interfacing, and a layer of satin chiffon (90% polyester 10% spandex).  For info on why chiffon, see:  https://pubs.acs.org/doi/10.1021/acsnano.0c03252


Quilters cotton, elastic, fleece scraps, nose thing, cut out of pattern, interfacing, satin.  You could make this with just two layers of cotton.  
You can increase/decrease the printing size of the pattern for children and men.  I printed it at 95% for my tween son and 105% for my husband (he has a big head!).  You might need to adjust other fabric and sewing measurements, depending on the size of your mask.


Sizes noted for standard mask.  I think I'd add a wee bit more length to the long elastic next time.  (I added an inch to each elastic length for my husband's larger mask and decreased 1/2" for my son.)



First, fold fabric in half and iron on interfacing.  Interfacing is optional, but adds body and extra filtration to the mask.



Put right sides together, with fold at the top.


Pin or clip on the satin layer if you are using it.  Mark 2" up from the open bottom on each side. This is where you will start and stop your stitching.



My sewing machine has a "satin" foot, pictured on the right.  If you use satin, I recommend this foot or the fabric won't feed well.  


Start sewing on one side at the 2" mark you made and continue around top and down the other side. Remember to backstitch or hand knot wherever you begin and end your stitches!


After you sew, clip the corners and make small cuts along the seam, or using pinking shears. This is so the seam will lay neatly and corners will be pointed.


Voila!



put right sides out.  On the front of your mask, find the center of the long (folded) side and mark.


Line up your nose piece at the center and mark around it, so you know where to sew.





Then slip your nose piece into place between the layers under the section you marked.


Use clips or pins to mark where the nose piece is and to hold it in place.


Flip to back and pin/clip fleece along top.



This rectangular piece will be folded in half later,  Here is the pattern on top, so you get an idea of the alignment of the mask and the location of the elastics.



The short elastic is at the corner. The longer one about 3"s in from each side.



Clip elastics into place, leaving the shorter elastic's end unclipped for now.  So, you have elastics, fleece, and nose piece all ready to be sewn with one top stitch.




Flip to front side and top stitch about 1/4" from the top, starting at corner with elastic.  Make sure to backstitch.  


When you get to the first pin where the nose piece is, pivot and sew downward until you are just past the nose piece.  Then pivot again and sew under it.  Pivot again at the end of the nose piece and stitch up. This creates a pocket to hold the nose piece in place.  Then, pivot again to finish top seam.


When you get to the very end, you can now attach the other side of the short elastic and sew into place at the corner.  Don't forget to backstitch. 


This is what the front looks like when you are done with this step.


The back.


Fold the rectangle in half and line up the pattern draw around it. Your nose piece will be bending the wrong direction for now.  You'll have to bend it back the other way when you flip the finished mask inside out.  


Side view. Now you see the way the mask will sit on your face. That whole top seam will form a U along your face with the nose piece at the crest of your nose.  The elastics wrap around the back of your head above your ears and at your  neck.


Sew along the line (back stitch at beginning and end yada yada yada)


Snip or cut with pinking shears along the seam


Pop the seam inside out, and here it is!


Masks at 105%, 100%, 95%, 90% (small child size)


Cow front view.


Side View


below the chin view.


On me (this one does not have the nose piece)


Side view.  No gaps and good fit along entire face, even without the nose piece. With a nose piece, it is an even better fit. The fleece makes it really comfortable even though it is a close fit.  I do end up with marks on my face after wearing it, but I guess that is to be expected with a tight fit. It doesn't irritate my face while wearing it, though.

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