Making a sculpted style face mask using the cotton face mask pattern found on the Maine Manufacturing Extension Partnership web page, with some of my own modifications.  The sculpted style of this mask is molded around your nose and chin, making it more comfortable to wear than the basic pleated style.

The original pattern with instructions can be downloaded here:  https://drive.google.com/file/d/1ihg0Cj4Nkkx-EOVwscn3Umaz6fqGLUp4/view?usp=sharing.

The image below is a section of the PDF pattern.  This blog shows how to assemble the pattern using my modifications.

For fabric use a tightly woven 100% cotton such as a premium quilter's fabric.

You'll need two lengths of 1/4" wide elastic - 10" long for men's mask, 9" long for women's mask.

For nose wires I'm using 12" pipe cleaners found in Walmart's craft department.

For the optional filters, I've been using a HEPA air furnace filter, taken apart and cut into small rectangles.

Cut the desired outer fabric, and the desired lining fabric.   Transfer pattern markings onto the outer and lining fabric.

Using a steam iron press the Tie Channel edge of the outside fabric in 5/8" and then fold under the raw edge a scant 1/4" on the raw edge and press.  This should give you a 3/8" channel for the tie.

Now fold the Tie Channel edge of the lining fabric in 1/2", fold again and press (1" total folded).  When the lining is placed over the outer fabric, the Tie Channel of the outer fabric will extend beyond the folded edge of the lining.

Stitch the pleats in the outer fabric and lining, just a short 3/4" or so seam.  Press the outer fabric pleat up, and press the lining fabric pleat down.  (You can also just fold the pleats and pin them, but I prefer to stitch them before sewing the outer and inner pieces together).

Stitch the two pieces of the outer fabric together along the center seam, using a 1/4" seam allowance.  Clip the edge along the curve, then use a tailor's ham to press. Topstitch on the outside along each side of the seam, which helps to help keep the seams lying flat when you insert or remove a filter.

Stitch the two pieces of the lining fabric together the same way, then clip, press and topstitch

• Tip:  Make the seam allowance of the lining fabric just a tiny bit wider along the center curve, which slightly reduces the bulk of the lining fabric and helps to keep the lining lying flat inside the mask once the mask is complete.    

Pin the lining over the outer fabric, right sides, together, and just check to make sure Tie Channel fold is the correct width.  You want the tie channel of the outer fabric to extend beyond the lining, so you can stitch the Tie Channel on the outer piece closed without stitching into the lining.  Make adjustments if necessary.

Fold back the outer fabric and double stitch the Tie Channel edge of the lining, leaving the outer fabric free.  Note that the Tie Channel of the outer fabric has not been finished at this point.

Pin and sew the outer and lining pieces together at the top and bottom.  Clip the seams edges, turn right side out and press.

Elastic

Cut two lengths of 1/4" wide elastic - 10" long for men's mask, 9" long for women's mask.

Join the two edges of each piece of elastic, overlapping 1/2", and tack.  I used the button setting on my sewing machine, one tack vertically and one horizontally.

Lay the elastic on the inside of the Tie Channel and fold the edge over.  Stitch along the edge of the Tie Channel, making sure the elastic isn't caught in the stitch.   (This allows you to later replace or resize the elastic if needed.)

Nose Wire

Fold a 12" pipe cleaner in half, or use stainless wire if available.  (Tip:  slightly folding the pipe cleaner in half a second time to mark the center helps to match up the center of the pipe cleaner with the center of the mask.)

Insert the pipe cleaner along the top edge, pin, and stitch the wire channel.

Filter

Cut a 5" square of filter fabric and trim to slightly round the edges.  I'm using a furnace filter, taken apart and unfolded - preferably HEPA.  Fold the filter in half and insert between the fabric layers.  Having the pocket opening on both sides makes it easier to reach in and unfold and straighten out the filter.

The Finished Mask