No Sew Big Hero 6 Masks {Superhero Mask Tutorial}

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Have you seen Big Hero 6 yet? If you haven’t you should, and if you have then I’m sure you are aware of why it is such a fabulous movie from a parent’s standpoint. Let’s face it, superheroes are great but sometimes the amount of violence they can dish out is a little disheartening, so having one like Baymax out there really calms my mind. It’s been a while since Judah really fell in love with a movie, but I had a feeling he would love this one so when I spotted it at Target I scooped it up for our weekly movie night. I have to say, I was really impressed with the values it addressed like the importance of helping people and high regard for the geeks out there. Oh yeah, and the fact that the geeks are the heroes and not some buff prince with shiny hair? Now that’s something I can get behind! So anyway, we all love the movie, and since I’m more than a little craft crazy I decided to create a set of adorable masks inspired by a few of the kids favorite heroes in the movie. I ended up making four different masks, so read on to check out the how to and choose your favorite!

These masks are completely no-sew and really simple to make. If you have some felt, scissors, elastic and an iron you can whip them up in no time! So here is what you need:

Various colors of regular felt (not stiff)
Yard of Pellon Wonder Under 805 interfacing (available at craft stores)
Thin white elastic
Chalk marker
Scissors
Iron
Small washcloth

Our first mask is going to be Baymax. This particular mask is sized to fit both my 2 and 4 year old so if you have bigger kids you will want to enlarge them a little bit to fit their faces. Each one of these masks is based off of the same original shape to make it easy so get your printer ready, click on this image and print out the page it takes you to at 100% on standard printer paper.

Now cut out your shapes, trace them onto the corresponding colors of felt and cut them out. Position them all on an ironing surface (wrong side up), cover with Pellon and then press your iron for around 5-6 seconds all over the felt. Cut the Pellon down to exact size and peel the backing off of your black and white pieces to reveal a shiny surface. Now lay the black in the center of your red shape, followed by the white on top of that with shiny side down. (In this next picture I didn’t use the black.)

Place a damp washcloth on top and press firmly for 10-15 seconds with your iron to seal your layers together. If you find they aren’t fused together then you can repeat for a few more seconds.

Once that is finished cut out a second large mask shape out of the same or similar colored felt to use as your backing so that it is smooth against your child’s face. Go ahead and peel the Pellon off of your original mask shape now.

Measure our your elastic to fit your child’s head and lay your mask on the ironing surface with the shiny side facing up. Position one end of your elastic on the outermost edge, then lay your extra mask shape on top of it and repeat the washcloth/iron step to seal in your elastic then do the same to the other side so that you have a complete loop. Don’t worry about slipping, once fused your elastic will hold firmly! Now fold the completed mask in half and cut out a rectangle large enough for your child to see through and then you are finished. Cute, right?

For the other masks you can use the same basic base pattern – I made a Hiro and a Honey Lemon mask just by slightly switching up the shape/cuts of the main layout and they turned out really well. I even made an alternate version of the Baymax mask too! Check out little miss modeling them for me, she just loves them!

Cute, right? These masks were super easy to make, and since they are no-sew and glue free there is virtually no mess to clean. These are great for parties or as a fun craft day activity with the kids.