Face Mask Tutorial Using Fusible Tape and a Hot Iron (No Elastic Required)

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Image Credit: Sara Albers

These days, a cloth face mask is your most important accessory. Sure, you can buy them online or in the store, but why not show off your personality with a DIY version instead? You don't even need to have a sewing machine for this easy, no-sew DIY, which uses iron-on tape. You just need woven cotton fabric in a pattern you love, fusible hemming tape, and an old cotton T-shirt to use as a substitute for elastic.

Image Credit: Sara Albers


This no-sew face mask is simple to make and will last you a while. We recommend hand washing and hanging it dry.

Things You'll Need

  • 100% woven cotton fabric

  • Old cotton T-shirt (to use as "elastic")

  • Fusible hemming tape, (3/8 inch)

  • Scissors

  • Iron

  • Ironing board

Image Credit: Sara Albers

Step 1: Cut Fabric

Cut two pieces of different patterned fabric into 9-inch-by-7-inch pieces. Next, use an old T-shirt to mimic the elastic: cut 1/4-inch strips of the T-shirt into 6-inch pieces. You will need two strips of 6-inch pieces per mask.

Image Credit: Sara Albers

Step 2: Attach Ear Loops

With the pattern side of your fabric facing up, place the ends of the T-shirt "elastic" into each corner of the fabric. Cut four small pieces of fusible tape, each 1/4-inch long, and then place in each corner. Then, lay the ends of the T-shirt "elastic" strip onto each piece of the tape and iron on (per the instructions on your fusible tape packaging). Allow to cool.

This creates the loops for the mask to stay on your face and attach around your ears.

TIP: Be sure to look at the directions on the fusible tape packaging regarding how long you should heat-set the tape onto the fabric, and at which iron setting.

Step 3: Layer the Fabric and Create Side Seams

Next, cut two 6 1/2-inch pieces of fusible tape. Lay these pieces on top of the T-shirt "elastic" strips at the side edges of the fabric. Then place your second piece of patterned fabric on top of that with the pattern side facing down. Iron the pieces together. Allow to cool.

Image Credit: Sara Albers

Step 4: Create Top Seam

Cut a 9-inch piece of fusible tape and lay in between the layers of fabric, on the top seam. Iron and then allow to cool.

Image Credit: Sara Albers

Step 5: Turn Fabric Inside Out

At the bottom of the mask that is still open, pull the fabric inside out so that the pattern side is now visible. Press with your hand to flatten.

Image Credit: Sara Albers

Step 6: Close Final Seam

Cut an 8 3/4-inch piece of fusible tape and lay in-between the remaining open seam. You will need to first roll in the fabric to get a nice seam. Iron and then allow to cool.

Image Credit: Sara Albers

Step 7: Make Pleats

Cut 12 pieces of 1/4-inch fusible tape. Now it is time to pleat. Pleating allows for the mask to expand over your nose and mouth. Fold down the top of mask 3/4 inch and add a piece of tape. Hold the iron down to fuse. You will need to add a weight of sorts to hold down the pleats while they set. We used a heavy book. Wait a few minutes and then fold down another pleat, and then do the same as above. You will make three pleats in total. Add fusible tape to the back side of the mask as well, under each pleat.

Image Credit: Sara Albers
Image Credit: Sara Albers

Your mask is now ready to go! We recommend washing it after every use and hang to dry.

Image Credit: Sara Albers
Image Credit: Sara Albers

Alice & Lois is a DIY and lifestyle blog where twin sisters Sara and Melissa share their inspiration, projects, connection and celebrate the good in life. They create inspiring posts centered around home, family, style and creativity, specializing in simple, yet sophisticated DIY projects. Sara and Melissa live in two very different places – Sara is in the heart of the midwest, Indianapolis and Melissa in the majestic ski town of Crested Butte, Colorado. Alice & Lois was named one of the Top 10 DIY and Decorating Blogs by the editors of Better Homes and Gardens in 2015 and 2016 and recently named one of the Top 30 DIY Blogs to Follow by Domino.

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