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How to Make My Disney Face Mask

by Jamie Rumph

I have had so many inquires about the mask I have been wearing to Disney World and truthfully, the same masks I wear everywhere I go.  A bonus to living by Disney is that adults wearing Mickey Mouse is 100% acceptable.  These are my people!

Disney face mask wearing at Animal Kingdom

So to answer the question, where do I get my masks?  I make them.  And sorry friends, I don’t sell them.

Planning worldwide vacations is my full-time job and leaves little time for much else!

However, I am happy to share my pattern with you and a small shop that will make them for you if you don’t sew!  I wish I could make them for you all but truthfully I am not that quick at it!

This mask may or may not work for you.  I feel like masks are a very personal thing.  So my best advice is to find one you love before being in a situation where you have to wear it for an extended period of time.

I tried out different masks on my trips to the grocery store (and Lowes, hello pool building, and landscaping) and was able to determine my preferences on those shorter outings.

My good friend Sophia, @i_lung_you made the pattern I like and has given me permission to share it with you.  So far it has been my favorite mask.

Personally I like that it fits the contour of my face and doesn’t crawl up into my eyes.  Since I’ve made all of mine myself I have been able to adjust the length of the elastic to fit.  I’ll share the lengths below.

Note: Sofia’s pattern includes 3 layers, one of them creating a picked for a filter. The ones I’ve been wearing and sharing with friends that you’ve seen in my stories only has two layers. I’ve eliminated the third pocket layer. You can choose which option you prefer.

It may seem a little complicated but honestly, once you’ve done it once, it’s pretty easy.

  1. Cut 2 of the pattern for each mask you’d like to make.  The face and the inside.   I use my fun fabric for the face and something coordinating for the inside.Cut mask fabric
  • For Jeremy, I use the men’s mask pattern with two pieces of 1/8″ elastic cut to 6 1/4″ long.  This fits Jeremy nicely and he’s 6″2.  I have been told by a couple of larger men that the mask is a little too small.  You can adjust by adding a 1/4″ around the mask pattern and/or extending the length of the elastic to 6 3/4″.
  • For myself and Adie, I use the women’s pattern and two pieces of 1/8″ elastic cut to 5 3/4″ long.  Adie and I are about the same size, 5’2″ size 6/8.
  • For Emmy, I use the Teens pattern with two pieces of 1/8″ elastic cut 5 1/4″ long.  Emmy is 11 and about average size.  I”ve also used this size for younger kids with shorter elastic and it works.  Sofia has also included a kids pattern too if you’d prefer that.

Honestly, the first round is going to be a little bit of trial and error to get it how you like it.  Try out my measurements and adjust them as needed.  I’ve also made these masks with 1/4″ elastic but it really makes a difference on the back of your ears to have the thinnest elastic as possible!  So stick to the 1/8″.


2.  Fold the mask in half, with the backside facing out.  Sew the two corners together to create a tent.  The iron, right side out to crease the seam you just sewed.sew darts into the two fabric mask pieces


3.  Place the two pieces together, the right side of the fabric to the right side of the fabric.  If that doesn’t sound confusing, I don’t know what does!  Look at the picture for clarification!  As I said, I plan vacations, not make or write “how to make masks!”

Pin them together and sew the top and the bottom with a 1/4″ seam leaving the ends open.  I like to turn the ends in 1/4″ of an inch before sewing the pieces together. pin masks together and sew along edges


4. Use the open ends to turn the mask right side out and then iron at the seams to get it to lay flat. turn mask right side out and iron it flat


5. Pin your 1/8″ elastic in the ends and then sew around the entire mask using a 1/8″ seam allowance.

Pin elastic and sew around the entire mask


6. Wear your mask, look cute, wash your hands,* and properly social distance!  Enjoy

Disney face mask at Magic Kingdom on reopening day

Fabrics & Mask Small Shop

For now, my mom and Adie have agreed to make masks for all of you. Please follow along on my Instagram for mask sales. I will post what’s available the day before it goes on sale in my stories and the time it will be available. When the sale opens, you’ll see it on my feed.

The fabric I’ve been wearing is from a few different places.  Hobby Lobby had the black mickey fabric years ago.  I’ve been hoarding it for years! I did find some on eBay – search black Mickey fabric and see what you come up with.

The Epcot fabric is from Spoonflower.  They have a number of great fabrics.

And my Porg Disney fabric I got from my friend Heather who has the most amazing stash of fabric for her craft business.  She makes some of the most fun things including Disney cups and of course now masks.

Currently, Heather sells Disney print masks in the rectangle style. You can follow her at Happily Ever Crafting on Instagram and on Facebook.



Kid’s Face Mask

Face Mask instructions

I hope this has been helpful and that you now have a few more resources for masks!


As for me, I’ll be happily booking your next vacation and saving mask making for the experts!  For a quote for your next vacation, please fill out my travel request form or email me at Jamie@LOTMV.com

And don’t forget to follow along on Instagram and Facebook 

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