This seems like all I've been doing the last week...... I have another request for 30 more today and it's just me.
Here is how I make the masks:
Prep work:
1. Digitize the outline of the panels
2. Digitize the nose sew pattern (arc)
3. Digitize the size sew seam to sew the sides with the ribbon
4. Make a jig using a 7"x7" or thereabout square hoop - cut a piece of posterboard to the size of your hoop, tape it on, and then I used PMI double sided pallet tape - this way you don't have to hoop a lot of the steps and save a lot of time! Sew your arc and the side seam onto the posterboard and then cutout out around the sew pattern of each. These are your guides.
5. Do the same for the outline sew pattern. I originally use used tape, but it tears and wears after quite a few. Do a posterboard like I did for step 4....I'll be doing that today.
Steps:
1 Sew the panels (2 per mask). Load material face up / material face down / (optional - but I use performance stabilizer as an extra layer). If using patterned material, you will swap the bottom 2 based upon left/right position.
2. Cut out the panels and flip them inside out. Use a pen to push the peaks and edges out if needed.
3. Using the nose/side jig, line up to pieces and embroider the arc - I do this and then move it over 2 mm and sew again for strength. I use small binder clips to keep them together, just in case.
4 Sew the sides with ribbon - flip material in, put ribbon in and tape ribbon to hoop (or use double sided tape).
I recommend doing all the panels in one run, then step 2, etc. that way you don't have to keep readjusting and reloading designs.
