Vacuum Formed Face Shield Visor

grabcad

I'm driven by the Prusa shield visor 3D print design, I decided to push myself to create something even more streamlined with fewer parts and lower production costs. This prototype won't match commercial designs in terms of comfort since it's non-adjustable, but its compactness might compensate for that limitation. Due to tapered edges, multiple units can be stacked together, allowing for efficient storage and shipping to hospitals at a reduced cost. I'm constrained by my lack of access to CNC machines and vacuum formers, which would undoubtedly make fabrication a breeze, potentially producing hundreds of units daily with minimal expense. If anyone has the means to utilize these tools, I'd love to see this design put through its paces. To further test its feasibility, someone could use a CNC to craft a mold from wood or rigid foam and attempt vacuum forming it using 0.75mm or 1mm PETG sheet – that would be incredibly valuable. As for the thinnest possible sheet, 0.5mm might work, but I worry it may stretch too far at the edges, compromising its structural integrity. The triangular protrusions on either side are designed to be cut about 7-10mm deep, serving as a secure anchor point for rubber bands or other restraints – depending on how they're processed. I'm open to adjusting and refining this design based on feedback; please share your thoughts!