3-Ply Cloth Bionicle Vahi Face Mask

About a year ago, a challenge seemed enticing, so I designed this sewing pattern for a LEGO Bionicle Vahi face mask. The pattern was created by tracing the outline of a scaled Vahi mask off a monitor, onto a piece of paper. Then the outline was cut and splayed to the angle of a fitted face mask and seam allowances were added. It's 3-ply, has a nose wire casing and includes a filter pocket. It’s made in XL size, because that seems to be the most common size people request.

It is a preliminary hand-drawn pattern, so lines are a bit rough. The steps also could be streamlined further if one had more fabric, but this one was designed from scraps.

The measurements are in US customary units. The pattern is for an XL size mask, but I have included my “Master block pattern” that has all of the additional sizes listed. You would need to re-scale the Vahi mask parts page in your printer settings for the smaller sizes. Cut out the pattern along the labeled line with your desired size.

*It is for personal/non-commercial use only. *Disclaimer: This mask design has not been tested for effectiveness and does not replace personal protective equipment like medical or construction masks. This mask does not prevent, protect from, or reduce viruses or diseases.

Notes: All of the seam allowances are ¼” unless otherwise stated. Pre-wash all cotton fabrics on warm or cold, prior to cutting to prevent shrinkage. Color-fasting may be necessary if the fabric dye “bleeds” when wet. Iron cotton fabrics before cutting.

Size guide:

2XL is for extra large faces and loosely fits on the neck. It was designed to accommodate facial swelling. 2XL mask dimensions are as follows: Length across center: 11” Width/height: 6.75”.

XL is designed to fit males & females with larger builds. XL dimensions are as follows: H 6” W 8.5”. Model shown is wearing size XL.

L fits average/larger medium males and females. L dimensions are as follows: H 5.25” W 9”.

M fits average females, males and teenagers. M dimensions are as follows: H 5” W 7.5”.

Care Instructions:

Wash before wearing. Hand wash cold, air dry. May be carefully ironed after fully dry. Do not iron the leather patch details or elastic straps, as they may melt.

Tools/Supplies needed:

Sewing machine

Overlock machine/serger (optional, zigzag stitching may be used)

Scissors

Tracing wheel

Pins and a hand sewing needle

Toothpicks (optional)

Ironing ham, mini ironing ham, or towels wadded into a ball shape.

Disappearing ink fabric marker

Fabri-tac or similar fabric glue

Washable glue stick or Lapel Stick

⅛” or ¼” wide elastic, preferably in black.

One nose wire. I use soft, plastic coated wires that are similar to twist ties.

Black, orange and white polyester sewing machine thread

Fabric needed (generous estimations to allow for miscuts):

About ½ yard of very dark gray cotton fabric for mask outer

About ½ yard of orange cotton fabric for Vahi mask details

About ½ yard of white muslin for the lining and filter pocket

⅛ to ¼ yard of black faux leather, or very thin real leather for the oval patch details