DIY Surgical Mask for Costume - Tutorial

Kiki wanted to be a surgeon for Halloween this year. It was easy enough to find her some scrubs and a stethoscope but she said she needed a surgical mask to complete her costume.

Here is a tutorial for a realistic looking play surgical mask. This is a one size fits all kind of mask; you just make the straps longer or shorter.


Here is what you will need:

Scrap of white flannel or cotton fabric, 5.5" by 6.75".
1/4" wide white double fold bias tape
White thread


First, cut out your 5 1/2" by 6 3/4" rectangle of white fabric:

To give your mask shape you are going to be pressing in some folds, kind of like accordion folds. Here is a chart with how to fold your mask:

First, using an erasable fabric pen, mark a line 3/4" from the top and 3/4" from the bottom. Mark a line every 3/8" between those lines. Now you will make the pleats in the mask. As marked on the chart, bring the line labeled A to the other line labeled A. Match B to B, C to C, and D to D.

Press each line with a hot iron to set the folds.

Pin the pleats to hold them in place.

Here is what it looks like from the side.

Now stitch across the narrow ends of the mask, like this:

Now cut a piece of bias tape just barely longer than the narrow end. Unfold the bias tape and pin it over the end of the mask, right sides together. Stitch on the fold closest to the edge.

Repeat for the other narrow side of the mask. 

Now trim the seam allowance a bit and fold the bias tape over the seam allowance. Pin well.

Top stitch along the edge of the bias tape. Repeat for the other side.

Trim the ends of the bias tape even with the edge of the mask. Cut two long pieces of bias tape, long enough to tie around the back of your head or around your ears. My mask ties around the ears.

Unfold the bias tape and pin it over the long edge of the mask, right sides together. Repeat for the other edge.

Stitch on the fold closest to the edge:

Now trim the seam and fold the bias tape over the seam allowance. Pin well.

Stitch from one end of the bias tape to the other.

Tie the ends together to fit around your ears or head. That's it! Your surgical mask is done!