“Face-Hugger” Halyard H600 Mask

This close-fitting pattern with a nose-wire and adjustable elastic was developed for Halyard H600 sterile cloth, a widely available fabric used to handle medical instruments in sterilization. Hospitals throw out large quantities of this material every day, and it has been shown to be effective in helping stop a high percentage of particle infiltration. It can also be used for other fabrics if you’d like.

The pattern for this mask was developed by engineer Roo Trimble and has dual cut-lines. The larger shaded area should be included as a seam allowance. If you’re using a standard sewing machine, trim the extra fabric to 1/8″ after sewing a seam. If you’re using a serger, you can let the serger cut this excess off.

The instructions and illustrations on this page are for sewing with a serger machine.


ยป Download the pattern here and print out at full scale (make sure and “fit to media” or “scale to page” functions are not checked in your Print command window)


Cutting 4 layers saves time! Line up 4 layers of Halyard H600 cloth and trace the pattern onto the top layer.


Cut all 4 layers.


Serging first seam-start from bottom and go to the peak.


This is a little tricky to keep curve going correctly as you serge off


Serge right off the fabric and don’t bother cutting just start serging the next piece.


Be careful when you serge over the middle seam


The last serged seam…then on to the regular machine


Fold hem over 3/8″


And fold one more time


Sew as close to edge as possible and be sure to back-tack at ends


A chain of 6 masks


Fold the edge over to outside 3/4″ ish (line up corners)


Press the fold to flatten it out a bit


Sew the wire holding seam be sure to back-tack at ends


26″ elastic


Thread elastic through hems with a big needle or a home-made bodkin made from a zip tie…


Tie off elastic-adjust as needed for a snug fit


Insert nose wire in open end, once in, bending it will hold it. (Nose wires can be made of any wire strong enough to hold its shape – strong twist ties, coffee bag closure wire strips, bendable cut sheet metal (deburred and with rounded corners for extra safety), etc.)


Finish seam by tucking tail back under stitches

See Roo sewing this mask on his 110 year old Singer sewing machine. This machine was in service during the 1918 Spanish Flu outbreak. For all we know, it has mask-making experience!

The finished mask should fit snugly after pinching the wire to fit closely over the nose and cheekbones, and adjusting the elastic to the desired length by tying extra knots if necessary.