Face Shield with Sealed Top (Foam Tape + 3-hole punch)

thingiverse

This is a 3DPrintable Face Shield, click here for a (CNC Friendly Face Shield)[https://www.thingiverse.com/thing:4262028] #Edits# * 4/4/2020: Uploaded v19, which reduces the print time by 50% from v12. * 3/30/2020: Uploaded v12, which replaces the holes on the visor with pegs and eliminates the need for zip ties. #Objective# Medical professionals anticipate a shortage of PPE during the COVID-19 pandemic and consider that a suitable Face Shield may be produced by makers as long as: * The face shield provides a tight seal around the forehead to prevent contamination * The shield has a considerable (>1.25") separation from the face for ventilation * The headband be soft and wide for comfort during long procedures * The shield be as transparent as possible Beyond that, we need to be able to make it: * Inexpensive * Manufacturable at scale by makers, and * Easy to assemble by doctors or hospital staff. Here, we try to share the best compromise we could find based on the local shortage of supplies. #STOP: There may be easier solutions in your area# The simplest solution for a Face Shield is to use a 1.25" (or greater) foam tape attached with self-adhesive to a transparent film with an elastic band. If you can source 1.25" foam tape effectively use that and do not print this. We could not find such tape locally, so we designed a 3DP headband that uses a widely available 3/4" foam tape to make a great seal to the forehead. #Disclaimer# Although we've consulted with medical personal to make the best possible solution, by downloading, making distributing, and using this, you agree to use it at your own risk. #How to Print# * Use the g-code for PETG on an MK3s (attached) or, * The model is optimized for a 0.4 mm nozzle. * Slice with 4 perimeters and less than 25% supports. * Infill layer angle 90 degrees [optional]. * For speed (~52 mins for v19), we are printing on a Prusa MK3 at (mm/s): Perimeters 55, External Perimeters 55, Infill 80, Solid infill 80, Top Solid Infill 80, First Layer 30. * Hospitals prefer PETG or ABS because they are familiar with those materials and are easier to wash and sterilize, but it prints well in PLA too. * Recommended [Face Shield Production Guidelines](https://docs.google.com/document/d/1STLEYvvPCiF46z09EgsbAtfmvy0W8tobQOGA7ozU5OU/) #Description# This Face Shield is designed to use inexpensive 3/4" insulation foam to create a comfortable and tight seal around the forehead. For the shield, it accepts any letter-sized or a4 transparent film, perforated with any 3-hole punch, and attached with zip ties. ##Estimated cost## * Headband (40 g of filament, volunteer print time and power): ~$0.90 * Foam Tape (10 in): $0.37 * Transparent Film: $0.18 * Elastic band: $0.22 * Zip-ties (3): $0.03 **Total: $1.70 per Face Shield** #Recommended Parts (in the US)# ##Foam## People have highlighted that the foam can result in a contamination challenge or hard to disinfect. Please consult with your target recipients to make sure the foam you use is appropriate. The ideal solution is a 3/4" thick foam that can either be washed, decontaminated, or replaced. ##EVA Foam## * Amazon (must be cut in strips and glued) [Craft Foam Sheets EVA Foam Sheets, 9.6×9.6 Inches, 3mm/5mm/7mm/10mm](https://www.amazon.com/9-6×9-6-Thickness-Cosplay-Costume-Scrapbooking/dp/B07G5CSWP8) * Amazon (High-Density Foam Tape for Doors and Windows Insulation Neoprene Rubber )[https://www.amazon.com/Adhesive-Insulation-Neoprene-Soundproofing-Stripping/dp/B0836Z1HN7] * Amazon (EVA Black Single-Sided Foam Tape is Highly Viscose, Waterproof)[https://www.amazon.com/Single-Sided-Viscose-Waterproof-Shockproof-soundproof/dp/B07QFPMLDF] * Amazon (uxcell 2 Pcs 50mm Width 3mm Thickness EVA Single Side Sponge Foam Tape)[https://www.amazon.com/uxcell-Thickness-Single-Sponge-Meters/dp/B072X7PGY5] * Amazon (1/4 Inch Wide x 1/8 Inch Thick Foam Self Adhesive Tape for Sound Insulation)[https://www.amazon.com/Adhesive-Insulation-Absorption-Weather-Stripping/dp/B07XX3HWTQ] * Amazon (LMHOME Foam Insulation Tape Adhesive, EVA Sponge Tape Foam Rubber 33 Ft- 1/8" x 2")[https://www.amazon.com/Insulation-Weatherstrip-Waterproof-Conditioning-Stripping/dp/B081YVSK68] * Amazon [Duck Brand Self Adhesive Foam Weatherstrip Seal for Extra Large Gaps, 3/4-Inch x 1/2-Inch x 10-Feet, 3 Rolls, 284424](https://www.amazon.com/Duck-Adhesive-Weatherstrip-10-Feet-284424/dp/B00MZHXIY6/) Suggested Foam Tapes: * Home Depot [Frost King: E/O 3/4 in. X 7/16 in. X 10 ft. Black High-Density Rubber Foam Weatherstrip Tape](https://www.homedepot.com/p/Frost-King-E-O-3-4-in-x-7-16-in-x-10-ft-Black-High-Density-Rubber-Foam-Weatherstrip-Tape-R734H/100047977). * Home Depot [Frost King 3/4 in. X 5/16 in. X 10 ft. Black Rubber Foam Weatherseal Tape](https://www.homedepot.com/p/Frost-King-3-4-in-x-5-16-in-x-10-ft-Black-Rubber-Foam-Weatherseal-Tape-R534H/202262324) * Home Depot [Frost King E/O 1-1/4 in. X 7/16 in. X 10 ft. Black High-Density Rubber Foam Weatherstrip Tape](https://www.homedepot.com/p/Frost-King-E-O-1-1-4-in-x-7-16-in-x-10-ft-Black-High-Density-Rubber-Foam-Weatherstrip-Tape-R516H/100090883) * Lowes (M-D 10-ft x 3/4-in Gray Window Seal Foam Window Weatherstrip)[https://www.lowes.com/pd/M-D-10-ft-x-3-4-in-Gray-Window-Seal-Foam-Window-Weatherstrip/1096049] Suggested Transparent Films: If you can, there are SVG (files) cut patterns for laser cutting or Cricut of the shields, but 3-hole punching should work too. * Amazon [BNC 10 Mil 8-1/2 x 11 Inches, Letter Size PVC Binding Covers](https://www.amazon.com/dp/B077H4635Y/) * Amazon [CFS Products 7 Mil 8-1/2 x 11 Inches PVC Binding Covers](https://www.amazon.com/gp/product/B07SB6ZKBD/) * Amazon [School Smart Write-On Transparency Films, 8-1/2 x 11 Inches, Clear](https://www.amazon.com/gp/product/B003V1BPXG/) * Curbell [PETG 20 Mil](https://www.curbellplastics.com/Shop-Materials/Product/PETG-Sheet/W01-03349/PETG-Sheet-Clear-(0-020-in-x-48-in-x-96-in)-FDA-Compliant-Film-2-sides) * Amazon (Confirm (and let me know) if these are clear enough) (Samsill 200 Super Heavyweight Sheet Protectors, 4.7 MIL Thick Top Loading)[https://www.amazon.com/Samsill-Heavyweight-Protectors-Thickness-Reinforced/dp/B07HZ39HJV] Zip-ties (Needed for v3 but NOT for v12): [Small Zip Ties (4")](https://www.amazon.com/Monday-HS-Plastic-Self-Locking-Electronics-Electrical/dp/B078NT5F2B/) Elastic Band: [3x5mm Natural Latex Rubber Band Tube](https://www.amazon.com/gp/product/B01MS6R5N0/) Please share if you find better alternatives or other sources globally so we can update these lists. #Distribution Model# We intend to recruit volunteers to 3DP headbands and donate packs of transparent film, foam, elastic, and zip-ties and then deliver these in bulk to hospitals and clinics where their staff can assemble individual shields as needed in seconds. Please reach out to your recipient before starting production to make sure they can accept whatever you make. #Requirements for assembly# * 3-hole puncher, drill, icepick to perforate the transparent film * Scissors, to cut the zip ties and pattern the transparent film #Variants# * 3-hole punch pegs (v19): Print Time 52 mins, 18 g. This version is the preferred one because it is easier to assemble and prints the fastest. * 3-hole punch pegs (v12): Print Time 1:50, 40 g. This version is the 2nd best because it is easier to assemble and robust. * 3-hole punch holes (v3): Print Time 2:15, 40 g. This version requires zip ties to secure the shield, but the attachment is the strongest. #Credit# We took inspiration from: * The [Prusa Face Shield RC2](https://www.prusaprinters.org/prints/25857-prusa-protective-face-shield-rc2) * The [NIS approved design](https://3dprint.nih.gov/discover/3dpx-013359) * The [snap-on design](https://www.thingiverse.com/thing:4233193) #Assembly# <ol> <li>Cut about 10" of elastic band and tie it to the headband.</li> <li>Cut about 10" of foam tape and glue to the headband.</li> <li>Make 3-holes on the clear plastic sheet using a 3-hole punch.</li> <li>Cut about 2" in diagonal on each of the bottom corners of the clear plastic sheet.</li> <li>For v12-v19 just stretch the shield to fit into the headband pegs. For v3 Attach the plastic sheet to the headband using zip-ties (pro tip, insert the zip-tie through the headband first) and cut the remainder.</li> </ol>