Updated Version 1.1 
 

 
 
THE SUAY FACE MASK PATTERN 
ONE PATTERN, TWO VARIATIONS: 
 
 
Variation A​: Self, Lining (Using Filter Material), Elastic, Nose Clip 
Variation B​: Self, Lining, Filter Pocket, Filter Insert, Elastic, Nose Clip 
 
 
 

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DISCLAIMER 
 
*This mask pattern is optimized for production, developed for a universal adult fit. There is an optional 
variation to the pattern (see below). These materials are just suggestions, as we have only been able to 
do particulate testing as included. Even so, our testing results are not guaranteed, and this mask pattern 
is not approved by the FDA or CDC, and these filter options have not been approved for mask making 
materials. We encourage you to stay curious and only use what you feel comfortable with, and always 
follow the guidance of the CDC available ​here​. 
 
We’re making this pattern available in order to contribute to the public good. We don’t want to be sued 
because of it. By accessing and/or using this document and the content it contains, you agree to the 
following terms:  
 
Suay, Inc. disclaims all express and implied warranties related to this mask pattern, including but not 
limited to its effectiveness or safety, to the fullest extent permitted by law, including but not limited to any 
implied warranties of merchantability or fitness for a particular purpose. Your use of this pattern is 
voluntary. If you use it, you do so at your own risk.  
 
Further, you fully and forever release and discharge Suay, Inc. and its respective affiliates, directors, 
officers, shareholders, employees, agents, and insurers, and all others involved in the creation of this 
pattern (collectively referred to as "Suay") from any and all injuries (including death), losses, damages, 
claims (including negligence claims), demands, lawsuits, expenses, and any other liability of any kind, of 
or to you, your property, or any other person, directly or indirectly arising out of or in connection with your 
use of this pattern, even if it is due to the negligence, injudicious act, omission, or other fault of Suay. 
 
You waive any and all claims against Suay, of any kind arising out of or attributable to the mask pattern, 
including those claims that may be unknown to you, or which you do not suspect to exist at this time. 
WITH THE INTENTION OF WAIVING ALL UNKNOWN AND UNSUSPECTED CLAIMS, YOU HEREBY 
EXPRESSLY WAIVE ALL RIGHTS, BENEFITS, AND PROTECTIONS YOU MAY HAVE UNDER CALIFORNIA 
CIVIL CODE SECTION 1542, WHICH READS AS FOLLOWS: “A general release does not extend to claims 
that the creditor or releasing party does not know or suspect to exist in his or her favor at the time of 
executing the release and that, if known by him or her, would have materially affected his or her 
settlement with the debtor or released party.” 
 

   

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 MATERIALS + TOOLS  
 
 
1. Tight Woven Cotton - washed and dried (​quilter’s cotton, tight woven muslin, old twill 
pants, etc.) 
2. Shop Towels​ (below recommendations)  
3. 2 yards of ⅜”-½” finished fold over elastic/braided elastic OR ½” -1” inch bias cut 
spandex, swimsuit material, or lycra 
4. Thread (​ cotton or synthetic) 
5. Fabric Scissors 
6. Ruler (if cutting bias) 
7. Stoked, curious, do-er attitude. (most importantly) 
 

OPTIONAL NOSE CLIP MATERIALS 

- Coffee Bag Tin Ties  
- Floral Wire 
- Twist Ties (for trash bags, bread bags, etc.) 
- Paper Clip 
 

OPTIONAL FILTER/LINING MATERIAL  

1. Wypall X80 Towel 
2. Zep Shop Towel 
3. Toolbox Shop Towel 
4. Scott Shop Towel 
5. Oil Absorbent Towels  
 
 
 
 
 
 
 
 

 
 

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 CONSTRUCTION INSTRUCTIONS 
VARIATION A
 
Step One:​ Cut your materials based on your preference  
 

 
 
 
 
 
 

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Step Two:​ Stitch all darts: self and lining 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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Step Three: ​Stitch chin gusset to face mask body out of self fabric. Repeat step for lining.  
 

 
 
 
 

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Step Four:​ Stitch self and lining together. Both face out. (face means front)  
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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Step Five:​ Attach side bindings to mask base 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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Step Six:​ Attach top and bottom binding to mask base  
(these bindings are the tie straps for adjustability) 
 

 
 
 

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Step Seven: ​Attach recommended nose clip to the top nose position of the mask body. It can be 
stitched into position or adhered to fabric. If you’re wanting to sew in an alternative nose clip 
between layers, position the nose clip and stitch around it between the lining and the self layers 
in step three. If using an adhesive back we recommend stitching down and tacking to ensure 
security.  

 
 
*Note: These steps can be adjusted based on your variation.  

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VARIATION B  
 
Step One:​ Cut your materials based on your preference  
 

 
 
 
Step Two:​ Stitch all darts: self, lining and filter pocket. 
 
Step Three: ​Stitch self fabric chin gusset to face mask body. Repeat step for lining.  
 
Step Four:​ Stitch self and lining together. Both face out. (face means front)  
 
 
 
 
 

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Step Five: ​Clean finish sides of filter pocket and attach filter pocket to self and lining (at 
notches) to make mask base 
 

 
 

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Step Six:​ Attach side bindings to mask base 
 
Step Seven:​ Attach top and bottom binding to mask base (these bindings are the tie straps for 
adjustability) 
 
Step Eight: ​Attach recommended nose clip to the top nose position of the mask base, can be 
stitched into position or adhered to fabric (if wanting to sew in an alternative nose clip between 
layers, position alternative nose clip and sew around it between the lining and the self layers in 
step three) If using an adhesive back we recommend stitching down and tacking to ensure 
security.  
*Note: These steps can be adjusted based on your variation.  
 

 
 
 
 
 
 

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 SUAY PRO TIPS  
 
TERMINOLOGY 
 
Self -​ main outer fabric, outer piece, “fashion fabric” etc. Welcome to the production 
sewing world! You got this!  
Clean finish​ - “twice-turn hem”, folded once @ ⅜” then again @ ⅜”  
Bias​ - when the fabric is cut at a 45 degree angle 

CHOOSING YOUR FABRICS 

There are multiple variations to this pattern. This is where you get to decide what mask version 
feels most suited for your needs. We recommend you read through the entire instructions and 
testing before you decide upon your materials. If this is a high use, lower exposure situation, 
perhaps a mask base constructed entirely out of tight weave cotton, with just a filter insert of 
your choice is best for you. 
 
If you are in a very high contact/high exposure situation and are looking for more 
disposable/sem-disposable options, using a filter material built in as your lining might suit. 
Again this is a personal choice based on needs/comfort.  
 

FOLDOVER ELASTIC VS. STRIP CUT KNIT FABRIC 

On our production floor we are attaching the elastic binding with a coverstitch machine. Most 
home sewers will not have access, so you could use a folder attachment on your home sewing 
machine. These can become fussy in addition to fold over elastic being trickier to source. 
Therefore, we came up with a slightly more cost effective and easier to obtain substitution: strip 
cut spandex, lycra, swim material, an old tshirt - whatever you got! If you have never made bias 
trim from your own fabric, please see ​this tutorial​. Use a zig zag stitch on your home machine to 
attach all trim, thus preventing thread from breaking as it stretches across the face and ties.  
 
There is no right or wrong way to attach your homemade binding! Yes, use old t-shirts if you 
want. You can attach the binding in 2 steps, if that helps: make a first pass attaching one side of 
the binding, then fold your material over and top stitch. Whatever you are most comfortable 
with!  
 

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THE IMPORTANCE OF USING TRIM THAT STRETCHES 
A tight fit is key here as it’s aiding keeping protection high. Substituting the trim for a woven, 
non-stretching trim instead of an elastic/knit could shift the ability to achieve a comfortable, 
more effective mask fit.  
 
 
 
 
 
 
 
 
 
 

   

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 WEAR + CARE 
TYING OPTIONS 
We have only particle tested the mask with tie option one, which is what we are recommending. 
However, if you find that uncomfortable please see option 2 as an alternative. Again, having a 
tight closure/seal is one of the best ways to heighten protection. 
   
TYING OPTION 1  TYING OPTION 2 

   

WASHING YOUR MASK 

If using Variation A with the filter sewn as the lining, the life of your mask will be more limited. 
Although we have tested our in-house made masks with a washing machine with positive 
varying degrees of success, w ​ e do not recommend machine wash for Variation A​.  
 
Our best result has been from hand washing with soap and hot water. Feel free to include 
whatever sanitizing components you feel comfortable with.  
 
Drying recommendations are as follows: line dry or machine tumble with a clean dry towel.  
 
 
FILTER SIZE 
 
We made the filter pattern a base size. It fits comfortably above the chin gusset on most folks. 

PLEASE feel free to adjust to your personal needs.     

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 TESTING 
We tested our masks for fit and filtration effectiveness on a PortaCount Pro.. The PortaCount 
measures particles ranging from .02-1 um. C ​ urrent estimates​ place the COVID-19 virus size at 
.125 microns. We are posting our lowest readings. We did get consistently higher readings but 
thought best to post lowest read.  
 
All supplies are in bold and have links in the supply list at the top of the document. 
 
The following aspects were important to the fit to filter particles. 
+ The chin piece (which is in our pattern) 
+ A bendable nose clip piece which can be made out of ​coffee bag tin ties​ or a sturdy twist 
tie, adjusted tightly around nose 
+ Elastic ties​ to give a tight fit to face 
 
When we made the masks out of the following materials they filtered out 87% of particles based 
on the Portacount fit test: 
+ One layer of oil absorbent towel + one layer of shop towel (Zep, Wypall or Toolbox 
brands) 
+ Two layers of shop towel (Zep, Wypall, or Toolbox brands 
 
When we made the mask out of t​ ight woven cotton​ and added the o ​ ptional pocket piece​, filling it 
with any of the following filters, the mask filtered out 82% of particles based on the Portacount 
fit test: 
-​Wypall X80 Towel 
-​Zep Shop Towel 
-​Toolbox Shop Towel 
 
When we made the mask out of t​ ight woven cotton​ and added the o ​ ptional pocket piece​, filling 
it with the following filter, the mask filtered out 70% of particles based on the Portacount fit test: 
-​Scott Shop Towel 
 
When we made the mask out of t​ ight woven cotton​ and added the o ​ ptional insert piece​ and 
filled it with n​ o filters​, the mask filtered out 52% of particles based on the Portacount fit test. 
 
We cannot guarantee these filtration percentages as they rely on the user to adjust fit and seal. 
We are not experts in the fields of masks or filtration, our attempts to quantify the effectiveness 
of our masks is a group of logical minded creatives trying our best to make something that we 
believe will help ​when the correct PPE is unavailable​.  
 
 
 

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