I recently spoke at the Homemade Mask Summit hosted by Just Wanna Quilt, the Newcomb Institute, Tulane University, along with the Phyllis M. Taylor Center for Social Innovation and Design Thinking, and the Albert Lepage Center for Entrepreneurship and Innovation at the Freeman School of Business.
Here is the presentation deck from that talk along with Q&A from the Summit.
This post specifically addresses the Fray Issue that has come up when sewing the MasksNow Pleated Pocket Mask. Troubleshooting for this issue is going to vary based on fabric thickness.
The issues
The leading edge of the pocket in the original instructions is not hemmed at the pocket opening and this can cause issues of fray especially in washing thick fabrics.
Options
Hem the double-folded edge at the beginning of the assembly between Step 1 and Step 2. This is what it would look like:
Hem the single-folded edge and nose wire pocket in one go at the beginning of the assembly between during Step 2. This is what it would look like:
Hem the single-folded edge with a zigzag stitch at the end of Step 1. This is a good solution for thick fabric.
Whipstitch the frayed edge. This is a good solution for masks that are already complete and that frayed in the wash. There are tons of hand sewing whipstitch edges tutorials on google. They will all work.
Glue… fabric. Depending on how bad the fraying is products like Fray-Check and other washable fabric glues can also be used. But I recommend this solution for the end-user only as you never know what folks are allergic to.
There are two ways to breakdown a t-shirt for mask ties, ties only or edge binding. This how-to post describes both.
For ties only
This method maximizes the shirt for strong ties that are 18 to 20 inches long when moderately stretched. This makes for a strong comfortable tie and a good mask fit.
For edge binding
This method results in ties that can be easily double folded to make edge binding and ties. For this method, you need to cut the strips wider so they are strong when stretched. If cut to thin with this method the ties will not hold the mask in a secure fit for long wear.
Lay the t-shirt out as flat as possible
Using a rotary cutter or very sharp scissors remove the sleeves and collar area from the body of the shirt.
Remove the hem of the shirt
Discard any narrow bits left over.
Cut horizontally across the body of the shirt at 1.75″ to 2″ lengths. This is easiest with a rotary cutter and a quilters ruler.
Discard any narrow bits left over.
Double fold and use as edge-binding. Stretch the strips to create round soft ties after sewing as binding. If you have odd short bits you need to combine to create strips be sure to sew them with a half-inch seam allowance and a zigzag stitch securely.