RC3 Compatible Face Shield for 0.8mm Nozzle

grabcad

***EXPERIMENTAL***I have yet to develop a proper shield for testing these components. I've created paper mock-ups based on the Prusa RC2 shield template and all of the holes align as they should, but this design still requires confirmation. The primary objective is to verify that the lower reinforcement snaps into place smoothly on a 0.020" / 0.5mm shield. If anyone has access to a printer with an 0.8mm nozzle and can obtain a shield for testing purposes, I would greatly appreciate any feedback. 2020-03-25 UPDATE:Prusa recently released the RC3 revision of their face shield. The only modified part was the headband; the hexagon cutouts were removed and openings added to the top and bottom faces to facilitate printing headbands in a stack. These new cutouts will not function well with wide-extrusion prints, so I have not incorporated them into my RC3 remix (I am exploring stacked printing with an 0.8mm nozzle). My updated models are identical to my RC2 remix, minus the hexagons. My objective for the RC2/RC3 remix is to utilize the high flow rate of large-diameter nozzles (larger than 0.4mm) to boost production speed. With this design and a print speed of 50mm/s, I can produce a set of components in approximately 45 minutes while maintaining the full 20mm headband height and the original Prusa strap hooks and shield mounting post layout. This design is intended to be completely cross-compatible with the original Prusa RC2/RC3 Face Shield. VARIANTS:Stiff/Flex:The stiff models feature consistent 2.88mm (3 perimeters) wall thickness throughout. The flex models have 2.88mm wall thickness for the front strap and 1.92mm (2 perimeters) wall thickness everywhere else. I find the stiff models to be more comfortable because the arms of the headband resist the elastic strap's tendency to apply pressure to the sides of the wearer's head with the ends of the arms. However, the flex models print faster and use less material, so I've included them. Brim:It is a common issue for the arms of the headband to lift off the print bed during printing, so I've added a small brim to each arm to enhance bed adhesion on the "Brim" models. The brim can be trimmed off with flush cutters. I use Simplify3D for slicing, so the settings below are organized as they appear in Simplify's profile system. These settings should translate to any slicer, although they may be named and/or organized differently. CRITICAL PRINT SETTINGS:Extruder:Nozzle Diameter: 0.8mmExtrusion Width: 0.96mmLayer:Primary Layer Height: 0.6mmOutline/Perimeter Shells: 3Infill:Interior Fill Percentage: 0% ;(Infill disabled)External Fill Pattern: Concentric Support:Generate Support Material: disabled ;(Supports disabled)Advanced:External Thin Wall Type: Allow single extrusion wallsInternal Thin Wall Type: Allow single extrusion fillI am still adjusting the remaining settings for PETG; I may return and update this with an optional settings list if I achieve a profile tuned in nicely. DESIGN REASONING:All wall thicknesses are multiples of the 0.96 extrusion width, ensuring that all walls (except at intersections) are printed with 2 or 3 straight perimeter passes. Due to the wide extrusion, we can safely disable infill and rely on perimeters to fill thicker areas, eliminating slow zigzag motions required by rectilinear infill. Additionally, the front strap has been trimmed down to a height of 10cm since the extra material there is not strictly necessary.