Button Headband Sewing Plans Possibilities

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This post is part of a series of posts about DIY/Open Source PPE.

CLICK HERE FOR A PATTERN WITH PHOTOS AND INSTRUCTIONS (it is in large print) After you click, you will see the pattern. Right click anywhere, and you will see "Save as" which allows you to save it.

Updated: 5:07 PM EST April 5

The point of the button headband is both comfort AND safety.
Masks that use elastic earloops can rub the ears to the point where they become raw and bleed. Button headbands are a way to prevent this.

Jersey or tshirt material can be used, but the pattern would likely have to be modified.

If you try this, please leave a comment with your results.


This Facebook group is great: Open Source COVID19 Medical Supplies.


Photos and sewing pattern by Amy Lindemann Chisowski

Metric for non-USA people.

No photo description available.

Headband with Buttons Pattern

Tools and surface must be disinfected before starting!


4" of fabric from bolt-tight woven cottons

4" of 1" elastic

two 1" buttons (can use 7/8)

Cutting and marking:

Find a scrap piece of fabric that isn’t slippery.

Use that scrap piece to make a pattern, using this pattern:

The pattern above is in inches.

Below, in millimeters.

You now have a pattern to guide your cutting. Lay the pattern out on your fabric. Pin if needed.

•Use the pattern to cut two pieces of cotton fabric.

•Cut 4" of 1" elastic. (If the elastic is too thin, it will be uncomfortable.) 

•Before you sew, make a mark for  a button 1-3/4" from an end. (If you finish the ends before making button placement, it’s 1-1/2" from end.)


1. Use ¼” seam allowance. Set stitch to a tight stitch. (On some machines, 2 is suggested).

2. Bring 2 fabric pieces together, pattern sides facing each other.

3. Insert elastic on 1 end of the fabric so that the bulk of the elastic is in between the 2 pieces of fabric and the end of the elastic aligns with the other end of the fabric. 

4. Pin in place.

5. Starting with the opposite end of the elastic end, start stitching on the outer long edge, going to the opposite end, pivoting at the corner. Continue in this manner until you finish at the outer long end opposite of where you started.

6. Turn the band right side out, pushing out the corners and using your fingers to pull the sides out flat. The elastic should be hanging out of one end of the band.

7. Use an iron to press it flat. Turn the fabric over ¼” at the unfinished end and press.

8. Reset your stitch to a wider setting (suggested: 3.5) 

9. Start at the end without elastic. Topstitch close to the edge along the first three sides of the band. 

10. Reinforce where the elastic is inserted at the end by sewing back and forth a couple times. 

As you approach the opposite end of the band, insert the tip of the unattached elastic end into the opening and topstitch over that. Reinforce it by stitching back and forth a couple of times. 

11. Pull on the elastic to make sure it is firmly in place.

12. Sew buttons in place.

You did it!

Image may contain: one or more people and closeup

Here is a picture of the prototype headband from the back. She made 2 adjustments to it that I incorporated into the pattern that is shown in this thread. First she pinned the elastic tighter because I had it too long. Second she folded up the width of the band because I made it too wide initially. The button sits centered without the fold.


Please comment with your ideas or questions.


Mask-match is a way for mask makers and those who need masks to connect.



From me, Steve the blog guy 🙂

I was working on AR learning game ideas before this situation, but have released this early because schools are closed. It is free. Oakbub and Bubiko's AR Alphabet.

5 thoughts on “Button Headband Sewing Plans Possibilities”

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  5. I’m the creator of the pattern. The video does not match the pattern, and in fact has the buttons placed way to forward on the band. What this will do is distort the mask on the face of the wearer. The band needs to be longer and the elastic shorter, so that the buttons can be placed further back. The pattern was confirmed by medical staff.

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