How to make a protective mask using your left over coffee bags

Just like everyone across the world, we have been trying to do our bit to help fight the covid-19 pandemic. What we've learnt is that little actions can make a big difference. 

Some of our clever staff and customers have found a genius way of reusing their strip seals from their Coaltown Coffee bags! They can slide into the nose bridge section of a protective mask to create a tighter fit across the face. 

 

Below is a step-by-step guide on how to make your own mask and reuse your bag seal:- 

DIY MASK INSTRUCTIONS 

TOOLS & MATERIALS REQUIRED 

• Scissors 
• Fabric
• Pins 
• Marking Chalk 
• Elastic or Ribbon

• Printer for Pattern

If you don’t have elastic or ribbon, you can get creative and use thinly cut strips of fabric to make straps that will tie around the mask wearer's head. 

*Fabric Suggestions 

The goal of these masks is to stop droplets and must be washable. Fabric must be breathable, without letting droplets through. 

 

MASK PATTERN 

 

Green -  Size Small

Red - Size Medium

Blue - Size Large 

You will need about 4 feet of ribbon or elastic cut into 4 equal parts. 

NOTE: PATTERN DOES NOT INCLUDE SEAM ALLOWANCE. 

Seam allowance is as standard added as 1cm/1.5cm.

Cut with right sides together: - 2 x from main fabric 

2x from lining fabric (Or cut 4 x from the same fabric) 

For scale, this box should be 4” when printed.

 

INSTRUCTIONS 

STEP 1: JOIN CENTRE SEAM 

- Join the curved seam that is centre of the mask by placing the good sides together and sewing them in place.

Repeat this step for both the outer (main) fabric, and the inner (lining) fabric. 

- Lay the coffee seal strip horizontally across the inside centre seam of the outer or inner fabric, where the mask would be touching the bridge of the nose and hand tack into place. This creates a small channel that the strip can sit in and once sewn to counter part will be hidden inside the mask. 

Repeat this step for both the outer (main) fabric, and the inner (lining) fabric. 

STEP 2: PRESS THE CENTRE SEAM 

This step has no functional value, it will only make your mask look better. Feel free to skip it. Caution: Do no iron over the coffee seal strip as it is plastic coated. 

- Press the seam allowance on the centre seam open so the seam lies as flat as possible. 

Repeat this step for both the outer (main) fabric, and the inner (lining) fabric. 

STEP 3: SEW THE OUTER TO THE INNER FABRIC AND ATTACH RIBBONS OR ELASTIC 

- Place your lining fabric down with the good side up. 

- Place two ribbons or elastic on the corners of one side
(right in the example) so they peek out just a bit from the mask, but the ribbon extends inwards. 

- Place the main fabric on top of the lining with the good side down. You should now have both layers of your mask on top of each other with good sides together and two ribbons sandwiched between them. 

- Pin through ribbons and layers to keep them in place on both sides.
After a few rounds, you will not need to pin and can just insert the ribbons as you approach the corner. 

- Lastly, sew around the mask, making sure to leave one side open so you flip the mask inside-out later. 

Be careful not to catch any of the ribbons in the seam elsewhere on the mask. Either guide them through the opening you leave on one side, or bunch them up in between the masks of your layer to keep them out of the way. 

  

 

- Flip your mask inside out so that the correct side of the fabric is facing outwards. Reach your hand into the side you left open and carefully pull the mask through to turn it. 

STEP 5 (optional): PRESS THE MASK 

STEP 6: CLOSE OPEN SIDE OF MASK AND EDGE-STITCH AROUND MASK 

- Make sure the open side is folded neatly inside, then edge-stitch around the entire mask. This will close the hole on the side give the mask and lining extra stability.  

STEP 7: MAKE MORE! 

That’s it! You can now wear your mask or send it to those in need.