Minimalist Face Shield - V2.0

prusaprinters

A Face Shield that prints in < 30 minutes. Easy to build with everyday parts & basic tools. UPDATES - V2.0 -- Forehead thickness increased for comfort. -- Offset forehead rest allows for stacked printing without significant increase in print times. -- Pins adjusted for standard U.S. 3-hole punch (4.25") -- Comment Response - Pins look "backward". This is intentional & helps the sheet snap on easily. Frame hooks are curved inward, toward head to keep parts protected behind the shield. The Minimalist Face Shield is a collaboration between designers and doctors that can be made quickly and efficiently by the home-based 3D print community. Prints are optimized for speed & minimal material usage. All non-printed parts are available off-the-shelf and material substitutions are easy. No special equipment or tools are required. The project goal was to build 500 units quickly in a home shop. The existing designs, based off the Prusa RC3 Shield, would have taken too long to print. The Prusa design also requires a laser cutter. This design reduces print time to ~30 min / unit for all parts and construction time is 2-3 minutes. The expected output is > 25 units / day / printer. Daily labor is ~ 1.5 hours. A home-based maker could be producing >150 units per week! The design takes into account doctor requirements, like comfort, cleanability and protection. It's currently being tried in several hospitals and improvements will be added as feedback is acquired. Thanks to Prusa for the base geometry and all the makers contributing great ideas - thinner profile, A4 paper, 3-hole punch, etc. The design is still young and is constantly evolving. Review and comments are most welcome! We hope this will get more shields into hospitals where they are needed right now. Disclaimer - The design & information here is provided as-is with no warranties written or implied. These designs have not been tested by or are they endorsed by any medical professionals. Fitness for use is solely the responsibility of the user. They are intended as a "better than nothing" solution in response to lack or equipment in the Covid-19 pandemic Print instructionsPrint Settings Printer brand: Prusa Printer: I3 MK3S Resolution: 0.3mm / 0.2mm Infill: 15% Filament_material: PLA, PLA+, (PETG or ABS probably but not tested) Print Notes: Frame - Print resolution = 0.3mm @ 100mm/sec. 2 layers - top, bottom, perimeter. Clips & Buttons = 0.2mm @ 70mm/sec. Materials Printed Parts - All parts have been test printed with PLA and PLA+. Regular PLA is flexible enough in this design but PLA+ is preferred. PETG & ABS may also work but haven't been tested. (Note - We have not spoken to any doctors that say heat resistance is a requirement.) Head Band - The clips are designed to work with elastic webbing (elastic bands). This is hard to get right now so the clips are available in different sizes (1/4", 3/8" & 1/2"). If webbing is not available the frame hooks are designed to hold rubber bands, elastic chord, a shoe lace, whatever is available. Face Shield & Hood - Prusa uses acrylic sheet (plexiglass). This is generally a special order item and needs to be cut to size. Instead, we are using off-the-shelf PVC or PET sold as "binding covers" or "presentation covers". The design is set up for 8.5x11" but A4 could be used too. Face Shield Material Link PVC - https://www.mybinding.com/7mil-crystal-clear-covers.html?sku=TC78.5x11S (Order Pre-Punched) Note on Cleaning - The hospital will likely be cleaning and reusing these. They use a variety of cleaners including - alcohol, bleach & peroxide. No degradation occurs with PLA or the PVC covers. Equipment 3D Printer (w/ minimum bed width of 205mm) Adjustable 3-Hole Paper Punch (0.28" holes) Scissors Xacto Knife Straight Edge Hot Knife or Flame Source. A standard handheld punch can be used if a 3-hole punch is not available. Construction & Assembly Safety The hospitals we've talked to are not considering these items sterile. However, passing along contaminated articles defeats the end-line goal fighting the pandemic. It would be prudent & responsible to wash hands, glove up & wear a face mask before beginning any construction or assembly. Part List 1 Frame, 1 Shield, 1 Hood, 2 Buttons, 2 Clips (base on elastic webbing size) Printed Parts Prints should need very little cleaning since supports are not required. Clean off any adhesive used on the print bed. Clear any flash where parts contact the forehead. Head Band Ideally the elastic webbing part is "hot cut" to 18" (460mm). If no hot cutter is available then burn the ends with a flame to keep them from fraying. Do this in a well ventilated area! These fumes are bad for you. Thread as shown. Shield & Hood The shield is one clear 8.5x11" sheet with 3 holes punched on the long edge. The hood is half a sheet, cut lengthwise, and 3 holes punched on the long edge. Two slits and four holes are located on the opposite side. See the DWG file for hole geometry and slit location. The rounded edges are non-critical and can be cut with scissors. We'll be making fixture to make the cutting operation easier. Design Questions Outstanding Resistance of materials (PLA, PLA+, PETG, ABS, PP & Elastic band) to cleaners (bleach, alcohol, peroxide)? Validate prints in PETG or ABS? Is the shield long enough? Designs range from 8.5 to 11". Final Assembly Begin by positioning the shield on the center hole in the frame. The fit will be snug. Carefully stretch one side over the side pin. Repeat on the other side. Don't flex the plastic too much or it will crack. Follow the same procedure for the hood. Insert the buttons from the inside, beginning with the outside hole first. Then attach the inside hole. The front panel of the hood should lie over the side panels. Clip in the headband & adjust to fit.