Best Fabric for Face Masks Guide 

I. Introduction 

Face masks have become a regular feature of life and are an accessory no one would like to do without even after the COVID-19 pandemic. Be it personal protection, social compliance or simple common sense, masks have gone from critical medical supplies to essential wardrobe staples. While some may focus on style, color or pattern, the most important thing is the mask’s fabric.

Face mask fabric should provide adequate protection, be comfortable to wear, breathable, and durable. A mask that is ineffective at particle-blocking, irritating to the skin, or which becomes unpleasant to wear after a few minutes completely undermines the very point of a mask. The right fabric should make a difference by filtering harmful particles and also make life comfortable for the wearer by being breathable and gentle on the skin. It is very important for those who wear masks for long durations.

The following face mask fabric guide is provided to help you understand different fabrics and decide on the best options for face coverings.

II. The Main Factors to Consider When Choosing Mask Fabric

There are several key factors that are important to consider when choosing face mask fabric. These factors help determine the best options and guide the decision-making process. Each of the following is an important factor that should not be overlooked. We will look at each in turn. 

A. Filtration Efficiency 

Filtration efficiency refers to the fabric’s ability to filter out or block microscopic airborne particles that may contain bacteria, viruses, or other contaminants. Filtration efficiency is essential in a mask’s ability to function as protection. The more particles a fabric can block or filter out, the more protective the mask will be.

The structure of the weave, the weight, and the number of layers of fabric all affect how well the mask filters out contaminants. Fabrics that are tightly woven, heavier in weight and multi-layered, generally have higher filtration efficiency.

Cotton fabrics that are tightly woven, like quilting cotton, tend to have higher filtration ability.

Properly constructed multi-layer cotton masks can achieve a filtration efficiency comparable to surgical masks in some cases.

Silk and chiffon have natural electrostatic filtering properties that make them effective by trapping particles through static charge.

Synthetic non-woven materials like polypropylene are also excellent at particle filtration, and highly effective in surgical masks when used in layers.

Tradeoff: 

As filtration increases, breathability decreases. 

B. Breathability 

Breathability is important because the wearer must be able to breathe comfortably in a mask, especially for long periods. It is an important factor for those who need to wear masks during exercise, or for long working shifts, or who live in hot and humid environments.

The more breathable a fabric, the more airflow it provides while still offering some filtration.

Lightweight cotton fabrics are well-known for their breathability. Examples include T-shirt material and quilting cotton. 

Silk and lightweight polyester blends are also breathable but may require additional layers for filtration.

Fabrics that are too dense, heavy, or multi-layered may not breathe well. This may make the mask uncomfortable to wear for extended periods and will encourage the wearer to fidget with or adjust the mask.

You can test breathability by holding the fabric tightly over your mouth and trying to breathe deeply. If the fabric feels uncomfortable or you can’t get enough air, it is likely not breathable.

C. Comfort and Skin Sensitivity 

Face masks are worn directly against the nose, cheeks and chin which are sensitive parts of the skin. Skin irritation can be caused by certain fabrics, their finishes and texture which is why fabric comfort and texture is so important.

Fabrics that are soft, smooth and have good moisture handling properties are more comfortable. Some examples include high-thread-count cotton, silk, bamboo and flannel.

People with sensitive skin or allergies should try to avoid synthetic fabrics. Such people may experience redness, itching, or other allergic reactions. Hypoallergenic fabrics such as organic cotton are ideal.

Rough, coarse, or stiff fabrics are generally not recommended for face masks as they are likely to irritate the skin after some time.

Comfort and fit are also about the temperature or thermal regulation provided by the fabric. Some feel very warm, hot and stuffy. Fabrics like breathable cotton and silk help keep the skin cool and dry.

D. Washability and Durability 

Face masks are intended to be reusable, so washability is a very important factor to consider. The mask fabric must be able to withstand repeated washings and dryings without losing its shape, filtration ability, or comfort.

Natural fabrics like cotton are machine washable and can go through several washes without significant deterioration, but they may shrink if pre-washed first.

Fabrics that are polyester or poly-cotton blends don’t shrink or wrinkle as much and often retain their shape better. Some synthetic coatings or treatments may wear off with washing, however.

Silk and other delicate fabrics may require hand washing or special care and may not be practical for high-use scenarios.

If a mask fabric deteriorates or loses its structure after a few washes, it has limited usefulness. Durability after repeated washings and drying is as important as the initial quality of the fabric.

Hand washing may not be as effective at removing germs and contaminants. The mask should ideally be machine washed in hot water and detergent.

E. Moisture Absorption and Wicking 

Breathing, talking and ambient humidity cause moisture buildup inside the mask. The ability of the mask to absorb or wick this moisture determines comfort and hygiene over time.

Cotton is highly absorbent and wicks away moisture and sweat, but the fabric itself may become damp and uncomfortable over time.

Polyester and polypropylene are moisture-wicking materials that draw sweat away from the skin and help the mask stay dry.

Silk is naturally moisture-wicking and can make a great lining material as it keeps skin dry and prevents bacterial buildup.

A wet or damp mask is uncomfortable and also a breeding ground for bacteria and other germs. Moisture absorption and wicking properties are important for both hygiene and comfort.

Absorbency (ability to capture moisture) and wicking (ability to disperse moisture) should ideally be balanced for the best comfort.

F. Fit and Structure 

The fit of the mask is also determined by the properties of the fabric used. A good face mask will have a properly structured mask fabric that fits snugly and well against the face.

Fabrics should have adequate rigidity or structure so that the mask does not have excessive gaping, especially in the nose and cheek area.

Layered fabrics also provide more structure than single-layered fabrics and hold their shape better.

Stretchy or very soft fabrics may sag or deform and lose coverage and protection.

Fabrics can also be used in different layers for different purposes. Soft, smooth fabrics work well as mask linings that are closest to the skin. Sturdier poly-cotton blends are often used for the outer protective layer.

Fit is also determined by how the mask fabric works with the nose bridge, filter pocket (if needed) and ear loops for adjustability.

III. Best Fabrics for Face Masks 

When it comes to masks, not all fabric types are created equal. The most effective materials are breathable, have good filtration, are comfortable, and hold up to repeated washing. The top fabric choices below will work well for creating or purchasing a high-quality reusable mask.

A. Cotton 

Types: 

Quilting Cotton, T-Shirt Jersey, Cotton Blends 

One of the most versatile and highly recommended fabrics for homemade or reusable masks is cotton. Its natural fibers provide breathability, softness, and durability that is unmatched by other fabrics.

Quilting Cotton: 

Quilting cotton is a tightly woven cotton material used in many sewing projects. It’s thicker and more durable than standard cotton sheets or shirts, and has better filtration performance. The stiffness of quilting cotton also helps it hold its shape, which can improve the seal around the nose and mouth.

T-Shirt Jersey Cotton: 

Soft, stretchy, and comfortable, cotton jersey knit (used in T-shirts) makes a great comfort layer. However, its open weave makes it less effective at filtration unless layered with other materials.

Cotton Blends: 

Mixes of cotton and polyester or spandex (spandex-cotton blends) offer more durability and wrinkle resistance while remaining breathable. These are great choices for masks that will need to be washed frequently and worn for longer periods.

Pros: 

Breathable and skin-friendly 

Machine washable and reusable 

Easy to find in fabric stores and at home

Cons: 

Tends to absorb moisture (especially in humid conditions or after long use)

Less effective if not layered with other filtration materials

Layering techniques – using two or three layers of quilting cotton, for example – can greatly improve filtration, making it one of the top picks for DIY mask makers.

B. Silk 

Silk is a great fabric choice thanks to its natural electrostatic properties, which help trap airborne particles. The performance of silk is comparable to that of synthetic materials when used correctly.

Lightweight and breathable, silk also allows air to pass through while wicking away moisture and trapping particles.

Its smooth texture is gentle on the skin and helps to reduce friction, which can minimize skin irritation or acne (“maskne”) problems.

Silk also naturally repels moisture, which can be especially useful as an inner mask layer to keep the face dry.

Pros: 

Natural electrostatic charge enhances filtration 

Soft and luxurious on the skin 

Moisture-wicking ability 

Cons: 

Delicate and requires special care (hand-washing or gentle machine cycle)

Less durable over time than cotton or synthetics

Less readily available and more expensive 

Silk can be combined with other fabrics (such as cotton) to improve the overall performance of a mask without sacrificing comfort.

C. Polypropylene (Non-Woven Fabric) 

Polypropylene is a synthetic, non-woven fabric used in surgical masks and N95 respirators. It offers good filtration while still remaining breathable and lightweight.

In certain forms, such as reusable shopping bags made of spun-bond polypropylene, it can be washed and is therefore suitable for DIY mask inserts.

Can act as a filtration barrier when placed between two cotton or polyester fabric layers.

Available in melt-blown or spun-bond forms, depending on the application.

Pros: 

Excellent filtration efficiency 

Water-resistant surface repels droplets 

Can be used as a filter insert 

Cons: 

Not recommended for direct skin contact for extended periods (may be uncomfortable)

Not always available in fabric stores (sometimes available in reusable bags or filter sheets)

Must be washed carefully to avoid damage 

A cotton mask with a polypropylene layer in between blocks significantly more particles than a cotton-only mask.

D. Polyester and Synthetic Blends 

Polyester and polyester blends (such as poly-cotton) are often used in face masks, especially as an outer layer that repels moisture and adds durability.

Moisture-wicking abilities of polyester help disperse sweat or condensation, keeping inner mask layers dry.

Polyester also has great shape retention and wrinkle resistance, so masks made with polyester will last longer after repeated washing.

Polyester is generally less breathable than natural fibers like cotton, which can make a mask feel hot or stuffy if not properly ventilated.

Pros: 

Excellent moisture management 

Durable, easy-care, long-lasting 

Good at maintaining mask shape 

Cons: 

Breathability is worse than natural fabrics like cotton

May cause skin irritation or discomfort for some users

Can generate static build-up if not treated 

Polyester blends work well as a sturdy outer layer when paired with more breathable, softer inner materials.

E. Flannel 

Flannel is a soft, brushed cotton material that works great as an inner mask layer due to its soft texture and insulation properties.

When layered with quilting cotton or another tightly woven fabric, flannel significantly increases filtration by adding both physical and electrostatic barriers.

Its cozy texture is also very welcome in colder weather, where mask-wearers also need to stay warm.

Pros: 

Adds warmth and filtration capacity 

Soft and gentle against the skin 

Works well in multi-layer mask constructions 

Cons: 

Hot and sweaty in warm/humid weather 

May be uncomfortable as an outer layer in the wind/moisture

Slower to dry than other materials 

Flannel is recommended for use in masks for colder environments or for occasional wear rather than intense physical activities.

F. Hybrid Combinations 

Hybrid fabric combinations use two or more different fabrics to take advantage of their respective properties and create a mask with superior overall performance.

Cotton + Silk or Cotton + Chiffon: 

These fabric combinations provide both high filtration efficiency (due to electrostatic properties) as well as breathability.

Cotton + Polypropylene: 

Adds excellent particle filtration and durability, making it ideal for reusable masks that need extra protection.

Cotton + Flannel: 

Enhances filtration efficiency and provides additional warmth, which is perfect for cold climates.

Studies show that hybrid masks can perform as well or better than surgical masks when constructed properly.

Pros: 

Hybrid constructions can take advantage of the benefits of multiple fabrics (e.g., filtration + comfort + moisture control)

Hybrids are more customizable and adaptable to different environmental or user needs

Can result in much higher overall protective performance

Cons: 

Takes slightly more time and effort to sew or construct

Hybrid fabrics may need more care in laundering to maintain each fabric’s desirable properties

Layering must be done correctly, or it may reduce overall effectiveness

If you are serious about making the best reusable masks, hybrid fabric constructions provide the highest potential for both protection and comfort.

IV. Fabrics to Avoid for Face Masks 

Not all fabrics are good choices for making masks. Some materials offer little to no protection or can actually pose risks to the wearer. Masks should be made from tightly woven materials that help prevent transmission.

A. Stretchy Knit Fabrics 

Stretchy fabrics made from materials like spandex, lycra, and other highly elastic knits are bad choices for face masks.

Particles and droplets can easily pass through these materials due to large gaps in the fabric weave when stretched. Masks made from such fabrics also lose their shape quickly, providing very poor coverage of the face that must be constantly adjusted.

Reasons to Avoid: 

Insufficient filtration efficiency 

Shapeless and gaps easily form 

Coverage is poor during movement or wear 

Stretchy knits tend to remain ineffective at providing protection even when layered with other materials.

B. Open-Weave or Sheer Fabrics (Lace, Voile, etc.)

Decorative fabrics like lace, mesh, or voile have large open weaves or visible holes that make them completely ineffective at blocking droplets or particles.

These materials are often used for aesthetic purposes, but have no place in masks where health and safety are concerned.

Reasons to Avoid: 

No effective particle barrier 

Zero filtration or protection 

Potential false sense of security 

Even when multiple layers of such fabrics are used, they still provide far less protection than a single layer of tightly woven cotton.

C. Fabrics Treated with Chemicals 

Fabrics that have been chemically treated or coated (often to provide waterproofing, wrinkle resistance, or stain protection) should also be avoided.

Chemical treatments can include irritants or harmful substances that may cause skin reactions or respiratory discomfort when worn against the mouth and nose. Chemical-coated fabrics also tend to be less breathable.

Reasons to Avoid: 

Skin irritation/allergies 

Breathability can be impaired 

Chemicals may off-gas or break down over time (especially with repeated washing) reducing the fabric’s integrity

V. How Many Fabric Layers are Ideal? 

Choosing the number of fabric layers in a reusable fabric face mask is pivotal. It is one of the most important mask-making or mask-buying decisions, directly affecting the mask’s filtration efficiency and breathability. Various health organizations worldwide have provided guidelines on this topic.

A. Single vs. Double vs. Triple Layers 

1. WHO and CDC Recommendations 

The World Health Organization (WHO) and the Centers for Disease Control and Prevention (CDC) have stressed that multi-layered masks are significantly more protective than single-layer ones. Their research and experience have shown that the more fabric layers a mask has, the better it can filter out potentially harmful particles.

The WHO recommends that a proper cloth mask should have at least three layers, and this recommendation has been published on their website as follows:

Inner Layer: 

This layer is the one in contact with the face of the wearer and is responsible for absorbing the moisture in the exhaled breath.

Middle Layer: 

This acts as the filter layer which stops the particles from passing through.

Outer Layer:

 The outer layer of a cloth mask should be able to repel moisture, thereby protecting the wearer from droplets.

The CDC, on the other hand, has stated that “cloth masks should have at least two or preferably three layers of tightly woven fabric.”

A closer look at the guidelines reveals some similarities and differences between the WHO and CDC recommendations.

2. Performance Differences 

The number of fabric layers significantly affects both the performance and the breathability of the mask.

 Here is a quick breakdown of single-layer, double-layer, and triple-layer masks:

Single-Layer Masks 

Advantages:

 Lightweight and extremely breathable 

Disadvantages:

 Provides minimal particle filtration 

Use: 

Not recommended for public use or medical settings. Best used as a last resort 

Conclusion: 

The single-layer fabric mask is not good enough.

Double-Layer Masks 

Advantages: 

Provides a good balance between breathability and filtration; easier to make or sew.

Disadvantages: 

The airflow is slightly lower than in single-layer masks, but the filtration of droplets and particles is significantly better.

Conclusion: 

Good for everyday use when both layers use tightly woven cotton or similar protective fabric

Triple-Layer Masks 

Advantages: 

Offers the highest level of filtration among non-medical cloth masks. The middle layer acts as an additional barrier that can trap tiny particles.

Disadvantages:

 Can decrease breathability, especially if thick materials are used. The mask can be a little heavier on the face.

Conclusion: 

Recommended for use in crowded areas, healthcare settings, or by people who are vulnerable to respiratory diseases.

The studies have shown that by simply doubling the number of layers, the ability of the masks to filter out small particles can be doubled. However, more than three layers can be cumbersome and challenging to breathe through, reducing the practicality of wearing the mask for extended periods.

B. Inner and Outer Layer Material Choices 

In addition to the number of fabric layers in your mask, what materials you use for the inner and outer layer also matter. Simply stacking the same material to add layers may not be the most efficient way to make a mask. The best way to make a fabric mask is by choosing the right inner and outer layer material that will not only provide protection but also comfort.

1. Inner Layer Material (Cotton Recommended) 

The inner layer of your fabric mask is the one that touches your skin. It should be soft and comfortable to the touch, and it should also be able to absorb moisture.

Cloth masks usually use cotton fabrics like high-thread-count quilting cotton, cotton jersey (the material used for T-shirts), or cotton to line the inner layer of the mask.

The inner layer will help absorb the moisture from your breath while also preventing the mask from becoming damp and causing skin irritation or acne.

2. Middle (Filter) Layer Material 

The middle or filter layer of your fabric mask is not necessarily required. However, if you want to add a filter layer to your mask, you can use materials like non-woven polypropylene or other filter fabric inserts (such as PM2.5 filter inserts).

Some mask patterns also call for the use of interfacing or flannel for the middle layer, which works well as it adds both filtration and breathability to the mask.

3. Outer Layer Material (Synthetic or Polyester Recommended) 

The outer layer of the mask is the one that faces the environment. This is why the outer layer of your fabric mask should ideally be water and particle-repellent.

Polyester, poly-cotton blend, or water-repellent-treated cotton are ideal fabrics to use as the outer layer because they are water-repellent.

This will ensure that any droplets don’t soak into the mask, improving safety.

Best Practice Example: 

Inner Layer: 

Soft, breathable cotton 

Middle Layer: 

Non-woven polypropylene or flannel 

Outer Layer: 

Polyester or poly-cotton blend 

This combination of fabrics will give you the best protection while also being comfortable and breathable.

VI. Mask Care and Maintenance Tips Based on Fabric

A face mask, however effective, loses its protective power over time if not properly maintained. Regular washing, careful drying, correct storage, and timely replacement are all critical for reusable masks. Fabric composition can influence care procedures. 

A. Washing Recommendations 

1. Hot Water Washing 

Cloth face masks should be washed after each use according to CDC guidelines to eliminate bacteria, viruses, and other contaminants.

Hot water (at least 60°C/140°F) is recommended for most materials for effective sanitization.

Cotton and poly-cotton blends handle hot water well, while delicate materials like silk need cooler water and gentle handling.

Masks with non-woven polypropylene should be washed with care to prevent damage. Hand washing or a gentle machine cycle is recommended for such masks.

2. Gentle Detergents 

Use mild, fragrance-free detergents to avoid skin irritation.

Avoid using fabric softeners or bleach unless disinfection is necessary, as they can degrade the fibers and affect filtration efficiency.

Use specialty detergents that preserve fiber strength and softness for silk or delicate fabrics.

Regular washing keeps the mask hygienic and prevents unpleasant odors and bacteria build-up that could cause skin issues.

B. Drying and Storage 

1. Air Drying vs. Machine Drying 

Air drying the mask flat is the safest method to maintain its shape and structure, especially for masks made of delicate fabrics like silk or those with filter layers.

Machine drying on low heat is acceptable for sturdy fabrics such as cotton and polyester blends but may cause shrinkage or fiber wear over time.

Ensure the mask is completely dry before reuse, as damp masks can promote mold and bacterial growth.

2. Proper Storage to Maintain Cleanliness 

Store clean, dry masks in sealed plastic bags or breathable fabric pouches to keep them safe from dust and contaminants.

Avoid leaving masks exposed in bags, pockets, or countertops where they can collect germs.

Keep separate containers for clean and used masks to avoid cross-contamination.

Good storage practices extend the mask’s lifespan and preserve its protective capabilities.

C. When to Replace Fabric Masks 

No matter how well you make or take care of your mask, it will eventually wear out with time. When it happens, it is important to know when to replace your fabric mask for continued safety.

1. Signs of Wear and Tear 

Frayed edges, thinning material, or visible holes are all signs that a mask is no longer effective.

Loose ear loops or ties can also reduce the quality of fit, allowing unfiltered air to pass through.

Rough, stiff, or brittle mask fabric after washing may indicate reduced effectiveness.

2. Loss of Shape or Fit 

A mask that can no longer fit snugly against the nose, cheeks, or chin is no longer adequate protection.

Broken elastic ear loops or seams that have stretched or torn can reduce mask functionality.

When a mask can no longer hold its shape, especially over the nose bridge or chin, it should be replaced.

3. General Replacement Guidelines 

Cotton masks: 

Can usually last for 30–50 washes depending on the quality of the fabric and how well it is taken care of.

Silk or delicate masks: 

Need replacement after fewer washes, especially if there are signs of fiber breakdown.

Polypropylene-based masks: 

May wear out faster if exposed to harsh washing or drying conditions.

VII. DIY Tips: Make Your Own Fabric Masks 

It has never been easier or more cost-effective to make reusable masks than now when the materials are readily available at home or easily purchased from stores or online. In fact, making your own face mask at home can be a satisfying and fun experience, allowing you to choose any fabric and style you like and adjusting it to your preferred fit and comfort level. Sewn or no-sew masks can be made from common household textiles and should be comfortable, safe, and effective if made with a little planning.

A. Most Effective Patterns for Fabric Masks 

Fabric masks can be designed in a variety of ways, each with advantages and drawbacks in filtration and fit. Patterns vary according to the shape and features of the design, your face shape and size, and the fabric you want to use. Masks may be flat, pleated, or contoured to your nose and chin, with some including special features like filter pockets, nose wires, and elastic straps. 

There are countless DIY patterns available in print and online; the 3 most common and recommended are:

1. Pleated Style Masks 

Description: 

Mask has the same overall design as a disposable surgical mask, but pleats are horizontal.

Benefits: 

Fit can be adjusted over the nose and chin.

Expandable to cover more of the face. 

Compatible with most fabrics, including cotton and cotton blends.

Fabric Considerations: 

Medium-weight quilting cotton works best. 

Better protection with double or triple-layering. 

Retains shape after repeated washings. 

2. Fitted (Contoured) Masks 

Description: 

Mask is curved to fit the nose and chin for a snugger fit.

Benefits: 

Better seals around the face. 

Ideal for glasses wearers to prevent fogging. 

Requires more precise cutting and sewing. 

Fabric Considerations: 

Tightly woven cotton or cotton-poly blends work well.

Channel for nose wire is common. 

Pocket designs are often included. 

3. Pocket Style Masks (Filter Masks) 

Description:

 Has a pocket between two fabric layers for removable filters.

Benefits: 

Personalizable filtration. 

Can include additional polypropylene layers or PM2.5 inserts.

Good balance between breathability and filtration. 

Fabric Considerations: 

Use cotton for both inner and outer layers.

Inner layer is cut large enough to form a pocket for non-woven inserts.

These three basic patterns allow for variations in number of layers, mask structure, and other features for comfort and fit. Choose according to your sewing abilities and the mask features you prefer.

B. Filter Inserts 

Filter inserts made of suitable fabric can enhance the filtration capability of fabric masks and may be used to make them more protective. Certain mask patterns and designs include a pocket or space for a removable filter insert, which can then be replaced or cleaned when soiled or used up. Filter options and important notes: 

1. Compatible Fabrics for Filter Layers 

Polypropylene (Non-Woven): 

This is the most highly recommended filter material.

Locate it in reusable grocery bags or breathable, safe vacuum cleaner bags.

Melt-Blown Fabric: 

Used in surgical masks and some cloth mask designs but harder to source at home.

Flannel: 

Adds particle capture potential when used as a middle layer, even if it is not a removable pocket.

Interfacing Material: 

Fusible or sew-in interfacing can be a static-charged filter layer (provided it is breathable and non-toxic).

Coffee Filters/Paper Towels (Emergency Use): 

Disposable inserts for use in a pinch; not washable and will degrade after 1-2 uses.

2. Important Considerations 

Filters must allow air to pass through; otherwise, they can make it hard to breathe.

Non-woven materials are generally better as they can capture particles and repel moisture.

Do not use materials that contain fiberglass, which is very dangerous if inhaled.

CDC recommends that removable filters be changed daily or after heavy use.

C. Sewing and No-Sew Options 

If you have a sewing machine, or even if you don’t, you can easily make washable, reusable masks at home that offer reliable and reusable face protection. Your choice of mask-making technique will determine the types of fabric you can use and how long your mask will last.

1. Sewing Options 

Sewn Masks (Machine or Hand-Stitched): 

Best overall as they offer superior structure, fit, and potential for multiple layers.

Can include filter pockets, nose wire channels, and elastic ear loops.

Recommended fabric types:

 quilt cotton, poly-cotton blends, flannel. 

Machines can sew multiple layers of fabric, but hand-stitching is possible for simple single-layer or double-layer masks.

Important Sewing Tips: 

Pre-wash all fabrics to avoid shrinkage after the mask is completed.

Use matching thread types (cotton thread for cotton masks).

Double stitch high-stress areas like ear loops. 

2. No-Sew Options 

Bandana and T-Shirt Masks: 

Fast, easy folding methods secured with elastic bands or ties.

Good for emergencies or light use only. 

Poor filtration without additional layers. 

Adhesive and Iron-On Designs: 

Use fabric glue or fusible interfacing to bond fabrics together.

Low durability and more suited to lighter use.

Fabric Considerations for No-Sew Masks: 

Choose tightly woven fabrics like T-shirt jersey or bandanas.

Do not use slippery materials like silk, which don’t hold their shape without stitching.

Mask-making with no sewing offers the quickest way to get masks that can be used temporarily; however, sewn masks are a much better option for regular use.

IX. Frequently Asked Questions (FAQs) 

Mask users have common questions about using, washing, and selecting fabrics for making or buying masks. 

Here are detailed answers to some of the most frequent questions:

A. What Fabric is the Most Breathable for Masks?

Cotton is considered the most breathable fabric for masks, particularly high-thread-count quilting cotton or T-shirt jersey material. Breathable fabrics are more comfortable to wear for longer periods. 

Other options include: 

Silk (inner layer)—it is moisture-wicking and gentle on the skin.

Polyester blends—less breathable but moisture-repellent for outer layers.

Use breathable cotton as the inner layer, and layer it with a filter material or water-repellent outer fabric for optimal protection.

B. Are Multiple Fabric Layers Really Necessary? 

Yes, more layers mean greater filtration efficiency of the mask:

One layer has the least protection—should only be used in emergencies.

Two layers provide a basic protection barrier and are best for lower-risk situations.

Three layers (WHO’s recommendation) offer the best particle filtration, breathability, and moisture management.

Benefits of multiple layers: 

Inner layer—absorbs moisture. 

Middle layer—forms a filter barrier. 

Outer layer—protects from external droplets. 

Multilayer construction can make masks more effective without significant sacrifice to comfort.

C. Can I Reuse and Wash All Fabric Masks?

Fabric masks are generally designed for reuse and can endure repeated washing if made from sturdy materials:

Cotton masks can last through 30–50 wash cycles before wearing out.

Poly-cotton blends are sturdier, retain shape better, and shrink less than 100% cotton.

Silk masks need delicate hand-washing and may not last as long.

Masks with filter inserts should have the filter removed before washing.

Important Notes for Washing Masks: 

Wash masks in hot water (60°C or higher) using a mild detergent.

Do not use bleach unless necessary as it may weaken natural fibers.

Check for signs of fabric weakening, loose threads, or shape changes after washing.

With proper care, masks can be washed and reused, helping to keep them clean and safe.

D. Is Cotton Better Than Synthetic for Mask Making?

Cotton is better than synthetic fabrics for the inner mask layer because it:

Is naturally breathable and can absorb moisture. 

Reduces the risk of skin irritation or rashes.

Is easy to clean and sanitize. 

Synthetic fabrics such as polyester offer benefits as an outer mask layer:

Repels moisture, blocking external droplets. 

Retains shape and mask structure better than cotton.

Best Practice: 

Opt for a cotton inner layer for comfort and moisture management.

Choose a synthetic or poly-cotton outer layer for droplet resistance and long-term durability.

Add an optional polypropylene filter layer in the middle for extra protection.

Mixing cotton and synthetic materials gives the wearer the advantages of both comfort and safety.

E. Which Fabric is Best for Sensitive Skin?

Sensitive skin may be irritated, red, or develop rashes or breakouts from wearing a mask for a long time.

 Choose any of these fabrics if you have sensitive skin:

Organic Cotton: 

Is hypoallergenic and soft to the touch. 

Made without harsh chemicals or dyes. 

Silk: 

Is naturally hypoallergenic. 

Great for reducing “maskne” (mask-acne). 

Smooth surface causes less friction with the skin.

Bamboo Fabric: 

Soft, antibacterial, and moisture-wicking. 

Ideal for sensitive or allergy-prone skin. 

Avoid the following fabrics for sensitive skin: 

Rough or coarse materials such as canvas. 

Treated or chemically finished synthetic fabrics that may cause irritation.

Stretchy knit fabrics that may retain moisture and bacteria.

IX. Final Thoughts 

Summary 

With the recent increase in need for well-constructed, reusable face masks, an understanding of the available fabrics, what they offer, and what they lack, has become a vital part of selecting and making masks for use. From your home-made masks to your purchase decisions at the store, your understanding of the differences in fabrics is the key to producing or selecting masks that are protective, wearable, and truly durable.

A. Review of Highest Rated Fabrics 

In this guide, we have discussed the several highly rated fabric options, which we have judged based on their filtration capacity, breathability, comfort, and care requirements. Here, we provide a short recap of the highest-scoring fabrics and their ideal use cases:

1. Cotton (Quilting Cotton, T-Shirt Fabric, Cotton Blends) 

+ Pros: 

Breathable, washable, widely available, generally affordable. 

Best Use: 

Optimal as an inner or middle layer for softness and moisture absorption.

Considerations: 

Perform best in two or three layers for enhanced filtration.

2. Silk 

+ Pros: 

Naturally electrostatic, soft, smooth, lightweight, moisture-wicking. 

Best Use:

 Comfortable as an inner layer for sensitive or acne-prone skin.

Considerations:

 Delicate; requires gentle washing, not as durable as cotton.

3. Polypropylene (Non-Woven Fabric) 

+ Pros: 

High filtration, water-resistant, used in surgical masks, N95 filters.

Best Use: 

As a middle filtration layer or a disposable filter insert.

Considerations: 

Not recommended for long-term direct skin contact. 

4. Polyester and Synthetic Blends 

+ Pros: 

Moisture-wicking, durable, good at holding shape, wrinkle-resistant.

Best Use: 

Outer layer to repel moisture and external droplets.

Considerations: 

Less breathable than cotton; inner layers should be natural.

5. Flannel 

+ Pros: 

Soft, high filtration when paired with cotton, retains warmth.

Best Use: 

Improves efficiency as an interior or middle layer in colder weather.

Considerations: 

Less ideal for hot weather, may retain moisture if not layered.

6. Hybrid Combinations 

+ Cotton + Silk: 

Great for breathability and electrostatic filtering.

+ Cotton + Polypropylene: 

High filtration efficiency and durability. 

+ Cotton + Flannel: 

Good for cold weather and improving particle capture.

Hybrid fabrics or masks (layered with more than one type of material) are typically rated as the best in scientific studies.

B. Balancing Filtration, Comfort, and Ease of Care 

Filtration is undeniably the most important aspect of a mask but that does not mean that all other factors should take a backseat to it. Masks are meant to be worn, and any garment that becomes uncomfortable to wear, hot, or otherwise irritating is at high risk of being removed entirely. Because of this, masks that are comfortable to wear, are breathable enough, and are also easy to care for will be the most used, and thus the most effective.

1. Filtration Levels Should Be Appropriate for Purpose

The riskier the environment (hospital, healthcare setting, crowds in a public place, etc. ), the more layers and/or filter inserts needed. 

For low-risk situations and brief outdoor use, a well-fitted two-layer cotton mask may be enough.

2. Comfort Affects Wear Time 

Comfortable masks made from soft, breathable, natural fabrics like high-thread-count cotton, or silk are more likely to be worn for longer periods.

Irritating, poor-fitting masks may be adjusted more frequently by the wearer, thus exposing the wearer and those around them to contamination.

3. Ease of Care Affects Durability and Cost 

Reusable masks must stand up to repeated washings and dryings without shrinking, warping, or the fibers deteriorating.

Best of these are cotton and poly-cotton blends, with silk and polypropylene layers needing gentler care.

A focus on these three factors when choosing fabrics and construction methods will result in masks that stay protective, useful, and comfortable for everyday use.

C. Prompt to Choose Fabric According to Intended Purpose—Daily Wear, High-Risk Environments, Workouts, etc.

Face masks are not a one-fabric-fits-all situation. The best fabric choice and mask design depend on your particular purpose and lifestyle needs. Below is some direction to help you select the best fabric choices based on some different use cases and situations:

1. Daily Wear and General Public Use 

Recommended Fabrics: 

Two or three layers of quilted cotton, with optional filter insert pocket.

Reason: 

Provides a good balance between breathability and protection for errands, commuting, or casual use.

Tips: 

Avoid bulky or overly hot materials. 

Proper fit around nose and chin is especially important.

2. High-Risk Environments (Crowded Indoor Spaces, Healthcare Settings) 

Recommended Fabrics: 

Triple-layer mask: 

Cotton inner layer + Polypropylene filter layer + Polyester outer layer.

Reason: 

Provides maximum particle filtration, moisture resistance, and overall durability.

Helps reduce wearer exposure in crowded or poorly ventilated places.

Tips: 

Opt for a fitted mask style with a nose bridge wire for a better seal.

Select fabrics that can handle frequent hot washings.

3. Workouts and Physical Activity 

Recommended Fabrics: 

Moisture-wicking polyester blends for outer layer. 

Soft cotton inner layer for comfort next to sweaty skin.

Reason: 

Keeps mask dry during heavy breathing and perspiration.

Allows for airflow during exercise. 

Tips: 

Ensure the mask has great breathability and stays secure during activity.

Select lightweight materials to prevent overheating. 

4. Sensitive Skin or Acne-Prone Wearers 

Recommended Fabrics: 

Silk or bamboo fabric as the inner layer.

Cotton or poly-cotton blend for the outer structure.

Reason: 

Helps prevent irritation, breakouts (“maskne”), and soothes sensitive skin.

Tips: 

Avoid synthetics in direct contact with the skin.

Use hypoallergenic, fragrance-free laundry detergent. 

5. Cold or Winter Weather 

Recommended Fabrics: 

Flannel inner layer + Quilted cotton outer layer. 

Reason: 

Offers warmth and increased filtration without too much breath restriction.

Tips: 

Ensure there is moisture control and the mask dries completely between uses.

Layer carefully to avoid excessive thickness that hinders breathability.

6. Quick or Emergency Masks (No-Sew) 

Recommended Fabrics: 

Tightly woven cotton bandanas or T-shirt fabric. 

Reason: 

Easy to fold and secure with rubber bands or ties in emergency situations.

Can provide basic droplet protection when folded into at least two layers.

Tips: 

Ensure at least two layers are used. 

Not ideal for long-term use or high-risk environments.