3D printed face shields: Difference between revisions

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[[File:Face shield front.jpg|200px]] [[File:Face shield side.jpg|350px]] [[File:Face shield top.jpg|350px]]
[[File:Doctor Sanjay Kurani of VMC 2.JPG|200px|thumb|Dr. Sanjay Kurani of VMC with Maker Nexus face shield]]
[[File:Regional_Medical_Center_San_Jose_-_Becka_Webber.JPG|thumb|200px|Regional Medical Center San Jose with MN face shields]]
 
Face shields are used by health care professionals to protect them when working with patients. Hospital supplies were running low. While they prefer to use commercially manufactured ones, in this emergency they were looking for alternative sources.
 
Visit [http://covidshieldnexus.org COVID Shield Nexus] for additional information on the overall program.


== Overview ==
== Overview ==
Face shields are used by health care professionals to protect them when working with patients. Hospital supplies are running low. While they prefer to use commercially manufactured ones, in this emergency they are looking for alternative sources.
[[File:Face shield front.jpg|200px|thumb|right|Front View]] [[File:Face shield side.jpg|200px|thumb|right|Side View]] [[File:Face shield top.jpg|200px|thumb|right|Top View showing wrap over]]
 
Maker Nexus has wrapped up our efforts on this project. With the help of over 600 volunteers around the country (and Canada) we have made and given away over 80,000 face shields. We also partnered with a local philanthropic company to make and give away 170,000 more. Over 250,000 face shields in total from this project! Other groups are still working on face shields. If you want to get involved you should contact them.
 
* [https://local.masksfordocs.com/us-ca-scsouth Masks For Docs]
* [https://getusppe.org/ Get Us PPE]
 
The headband portion of these shields is made on a 3D printer. If you have a 3D printer, you can make these. We delivered them to local hospitals.


The headband portion of these shields is made on a 3D printer. If you have a 3D printer, you can make these. We have several at Maker Nexus that will be running as long as we have supplies. We need volunteers come in to service the printing. We also need volunteers to assemble the final shields. We will deliver them to local hospitals.
'''In the News'''


* [https://docs.google.com/forms/d/e/1FAIpQLSe5uMbl2USWKg6Qi6HovydA6lteBgnRsIBWnQcJaL4x6OdryQ/viewform Sign up to use your own 3D printer] to help
* A mini documentary [https://www.nbcbayarea.com/news/coronavirus/museum-and-maker-space-design-safety-gear-for-bay-area-hospitals/2302179/ about MN and The Exploratorium]
* [https://docs.google.com/forms/d/e/1FAIpQLSetfP2_-Wh7nZehMFQyFvElZALMGc7BLJZd_7HZfZqNEdoWoA/viewform Sign up to receive face shields] for your health care facility
* A TV segment [https://sanfrancisco.cbslocal.com/video/4495791-maker-community-uses-3-d-printer-to-supply-ppe-to-health-professionals/ from KPIX]
* Watch a short [https://www.ktvu.com/news/covid-19-sunnyvale-company-designing-3d-protective-masks-to-meet-demand KTVU news report about our efforts.]
* A blog by [https://medium.com/@prithvisathiya/fighting-covid-19-2071e8b00b4c one of our community print team] talking about his experience.


[[MN COVID Response|Other COVID Projects]]  
[https://drive.google.com/drive/u/1/folders/1ctRiSGibdSyNa39tAXY4sKIrBgyTjnSg Our press kit]


Watch a short [https://www.ktvu.com/news/covid-19-sunnyvale-company-designing-3d-protective-masks-to-meet-demand KTVU news report about our efforts.]
'''How much do they cost?'''


<span style="background:#00FF00">[http://www.makernexus.org/donate Donate via Paypal]</span> to support COVID-19 response efforts by Maker Nexus.
​We gave these away, paying for them from donations. We did not sell them. Promises of donations or actual donations did not affect who was prioritized to receive the PPE. The allocation team was not told who has donated. However, they cost us about $5 each to make. Donations were critical for us to be able to keep producing. We were pleased that so many donated to support the effort.  
​
​
​
'''Was there really a need?'''


== Is there really a need? ==
* We heard from friends that "nurses are cutting up plastic soda bottles to make face shields, using saran wrap on top of N95 masks to allow for multi-use."
* We've heard from friends that "nurses are cutting up plastic soda bottles to make face shields, using saran wrap on top of N95 masks to allow for multi-use."
* One local nurse said they are making face shields from cut up shower curtains and hot glue guns.
* One local nurse said they are making face shields from cut up shower curtains and hot glue guns.
* In reviewing the current design: "The nurses were over the moon about how easily the shields can be disassembled and sterilized."
* A nurse from Marin called us and I got her hooked into the allocation process and told her they were free. She started crying on the phone. - JimS


In reviewing the current design: "The nurses were over the moon about how easily the shields can be disassembled and sterilized."
Some photos of [https://www.covidshieldnexus.org/front-line-heroes front line workers with Maker Nexus face shields].


We are ramping up to make 1,000 a week, maybe more.
See [[Face Shield User Stories|stories from those who have received face shields from us]].


If your health care facility needs face shields, fill in this form:


<span style="background:#00FFFF">[https://docs.google.com/forms/d/e/1FAIpQLSetfP2_-Wh7nZehMFQyFvElZALMGc7BLJZd_7HZfZqNEdoWoA/viewform?usp=sf_link My Facility Needs Face Shields]</span> (click the link)
'''How do I get some?'''


== 3D Print Parts At Home ==
We stopped our efforts because there are now shields available from many retail outlets. Do a web search on "face shields".


=== Use Your 3D Printer for good ===
If you need them for free, you could contact one of the following organizations:


==== Sign up ====
* [https://getusppe.org/ Get Us PPE]
We are establishing a network of 3D printer owners who can make the headbands for us. You make them and deliver them to our facility where we do the assembly and get them to the hospitals. If you want to be part of our network, fill in this form and we will contact you:
* [https://masksfordocs.com/ Masks For Docs]


<span style="background:#00FFFF">[https://docs.google.com/forms/d/e/1FAIpQLSe5uMbl2USWKg6Qi6HovydA6lteBgnRsIBWnQcJaL4x6OdryQ/viewform I want to help make them]</span>
A link to [[MN COVID Response|Other COVID Projects]]


==== Report your progress ====
== 3D Print Parts At Home ==
If you've signed-up and started printing already:
[https://docs.google.com/spreadsheets/d/1Aoq7a0YbkPbGiMZGSxBgo0ySlgDWZHoaCvXc8sx9FU8/edit Keep us updated with your print progress].
Please request permission to access the file if you're prompted to, and we'll respond as quickly as we can.


=== What to do with the finished product ===
=== Use Your 3D Printer for good ===
When you have parts ready to deliver, please follow the following steps:
#  Fill out [https://docs.google.com/forms/d/e/1FAIpQLSdJfZz5M-xxQifJmFBdNQcn7c3i5eFabV7StA5ep9zsJuco9Q/viewform?usp=sf_link this form] with information about your donation (so we can track inventory)
#  Seal in plastic bag.
#  Label bag with your email, the version of face shield you printed, the material printed with (Currently RC2v1 is the most up to date part) and the date you closed the bag.
#  Mail to
Maker Nexus
234 E. Carribean Drive
Sunnyvale, CA 94089
OR
Deliver to us if you are local and it does not violate the Shelter In Place Order - please do not make a special trip for this - but if you are passing by on your way to get essential groceries and want to drop it off, that is acceptable - there is a box outside our front door where donated parts can be placed.
 
Please be sure you are following proper sanitation procedures when you bag parts - if possible, wear gloves and a breathing mask, wipe or spray with disinfectant if available.  We want to minimize the chance of cross-contamination.  After it reaches MN, we will be further disinfecting them before delivering to its end destination.


We are not in a position to supply you with filament. If we are successful at raising more money for this program, then we might be able to give you a new reel when you drop off 20 face shield sets.
'''Maker Nexus has ended this project.''' We appreciate all the work the distributed team has done. With your help we have been able to make and give away over 250,000 face shields across the US.


== 3D Print Directions ==
== 3D Print Directions ==
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==== PETG filament Sources ====
'''Filament'''


These face shields are best done with PETG filament. A 1kg spool can make about 20 units.
These face shields are best done with PETG filament. A 1kg spool can make about 20 units. They can be done with PLA but it is difficult to get them strong enough to handle all the bending.


* [http://matterhackers.com Matter Hackers]
The face shield stiffener at the bottom of the plastic shield can be printed in PLA. A 1kg spool can make about 180 units.
** 3mm product id # MF3CF7NH  1kg about $25
** 1.75mm product id # M3MY2VQG 1kg about $24 (only $20 each if you buy 5)
** 1.75mm product id #  MTVEPT25 10 pounds (4.5kg) about $185 It is a higher quality PETG filament, but is it really worth the extra cost?
 
==== PETG Sheet Sources ====
 
One 48x96 inch sheet can make about 24 shields.
 
* [http://www.piedmontplastics.com Piedmont Plastics] in San Leandro, CA. .020x48x96 CLR VIVAK PETG JFM  about $16/sheet.


=== Instructions ===
=== Instructions ===


==== Printer Settings ====
'''Printer Settings'''


Print with PETG for ease of sanitation - IPA, Hydrogen Peroxide, Bleach, and Acetic Acid up to 10% can all be safely used with PETG.
Print with '''PETG''' for ease of sanitation - IPA, Hydrogen Peroxide, Bleach, and Acetic Acid up to 10% can all be safely used with PETG.
If you don't have PETG, using '''ABS''' and '''PLA''' is also an approved option.


Print settings:
Print settings:
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=== Parts ===
=== Parts ===
We are focusing production on the Prusa RC2 headband with some modification to reduce weight and center the mounting pins, based on feedback from medical professionals.
We use a modified Prusa design. Our headbands maintain compatibility with the placement of the pins to mount the shield. After consultation with two local hospital teams, we made several changes to the original Prusa design.
If your printer is large enough to print this design, PLEASE switch production to that. If your printer cannot accommodate that, RC1 pieces are still helpful. See below for details on each.
* The shield mounting pins are moved up to the middle of the headband to eliminate a potential entry point for aerosols. When the shield is mounted to lower pins the hole in the shield is not completely covered by the headband.
* The flex points between the headband and the "wings" have a radius added. This makes it easier to clean. The original design had a narrow angle in that area.
* The headband is made narrower to print faster. We find that using PETG these headbands are very strong.
* The shield has an over-the-top dome that protects against droplets falling down onto the face.
Our design is, of course, released back to the world under the same CC licensing as the original. Links to our design files are on this page.  
 
==== What to print now ====
Please do not print additional parts for us.
 
==== Historic ====


==== RC2 + MakerNexus extensions (PREFERRED) ====
''Files for the parts we used to make our face shields''


The MakerNexus modifications [https://github.com/hzeller/prusa-covid19-shield-remix are on github].
Bottom Stiffeners
Easiest is to download the release at https://github.com/hzeller/prusa-covid19-shield-remix/releases (latest is v1.1)
 
[[File:prusa-bottom-part-plate.png|right]]
 
On one build-plate of a Prusa, we are able to fit 34 (might be a little bit more with more squeezing); it takes a little bit more than 8 hours, which is great for night-shifts, as there is no lost time. This also means that in optimal situations, we can get around 100 per day per printer.
 
GCode:
* [https://github.com/makernexus/prusa-covid19-shield-remix/raw/master/fab/bottoms-PETG-Prusa.gcode bottoms-PETG-Prusa.gcode] '''PETG''' for Prusa MK3s
* [https://github.com/makernexus/prusa-covid19-shield-remix/raw/master/fab/bottoms-PLA-Prusa.gcode bottoms-PLA-Prusa.gcode] '''PETG''' for Prusa MK3s
* [https://github.com/makernexus/prusa-covid19-shield-remix/raw/master/plate-full-of-bottom-supports.3mf plate-full-of-bottom-supports.3mf] '''3mf''' Project file for prusa-slicer
* [https://github.com/makernexus/prusa-covid19-shield-remix/raw/master/fab/bottom_reinforcement.stl bottom_reinfocement.stl] '''STL''' do manually fill your build-plate and slice.
 
 
 
Head bands
 
Most important change in our headband design is that the pins are centered in the headband, so that there is something covering the shield punch, making a better seal. Also, the radii in the crevices are larger than the original to facilitate easier sanitation.
 
Latest release is v1.9 (2020-04-06)


This archive contains (next to the source files) the following files used used to print, which you also can download here:
This archive contains (next to the source files) the following files used used to print, which you also can download here:


* '''Ready-to-go''': [https://github.com/hzeller/prusa-covid19-shield-remix/raw/master/normal_shield_0.3mm_PETG_MK3S.gcode normal_shield_0.3mm_PETG_MK3S.gcode] '''GCode''' for MK3S printer for PETG 0.3mm, 3 shells, 30% infill; printing two headbands. You can use this directly in your Prusa MK3/MK3S printer. I change the print speed to 130% on the printer and the output is still excellent. Print time ~4:30h with 130% speed.
* '''Ready-to-go GCode''': [https://github.com/makernexus/prusa-covid19-shield-remix/raw/v1.9/fab/T9-PETG-Prusa.gcode T9-PETG-Prusa.gcode] (right click, download or ''save link as...'') for '''PETG''', [https://github.com/makernexus/prusa-covid19-shield-remix/raw/v1.9/fab/T9-PLA-Prusa.gcode T9-PLA-Prusa.gcode] for '''PLA'''. This prints two headbands and two bottom stabilizers. Using print-speed of 130% on the Prusa seems to work fine. If you use '''ABS''', please use the files below to slice for your printer. These print with little 'D-shaped' supports in front of the pins, that should break off easily.
* '''modify print parameters''' [https://github.com/hzeller/prusa-covid19-shield-remix/raw/master/normal_shield.3mf normal_shield.3mf] '''3MF''' file to load in slicer. Contains support-material setup. It works in a [https://www.prusa3d.com/prusaslicer/ prusa-slicer] (I use version 2.2.0), and should also work in other slicers.
* '''3MF slicer project file''' [https://github.com/makernexus/prusa-covid19-shield-remix/raw/v1.9/thin_shield.3mf thin_shield.3mf] for PETG and [https://github.com/makernexus/prusa-covid19-shield-remix/raw/v1.9/thin_pla_shield.3mf thin_pla_shield.3mf] for PLA. This allows you to choose placement, temperatures, select which parts to print on the bed etc.
* '''slice yourself''' [https://github.com/hzeller/prusa-covid19-shield-remix/raw/master/normal_shield_with_support.stl normal_shield_with_support.stl] The '''STL''' file. It already contains integrated supports for the pins (there is also one without support if you want to do that in the slicer).
* '''slice yourself''' [https://github.com/makernexus/prusa-covid19-shield-remix/raw/v1.9/fab/thin_shield_with_support.stl thin_shield_with_support.stl] (right click, download or ''save link as...'') for PETG, [https://github.com/makernexus/prusa-covid19-shield-remix/raw/v1.9/fab/thin_pla_shield_with_support.stl thin_pla_shield_with_support.stl] for PLA. There is also a no-support stl version in case you want to add support for the front-pins yourself in your slicer. If you _do_ print with build-in supports, make sure to enable the ''''Detect Thin Walls'''' feature in your slicer.
 
Also please print one [https://github.com/makernexus/prusa-covid19-shield-remix/raw/master/fab/bottom_reinforcement.stl bottom_reinforcement.stl] per headband (sometimes it is more efficient to do that separately). If you slice the version with built-in support, make sure to have 'enable thin wall detection' in your slicer. The 3mf files already have that enabled.


==== Older Versions ====
If your printer can't fit a headband, you can still help and print the bottom parts, stabilizing the shield plastic: Print as many [https://github.com/makernexus/prusa-covid19-shield-remix/raw/master/baseline/bottom_reinforcement.stl bottom_reinforcement.stl] that you fit on your print-bed: we need them as many people with larger print-beds focus on the headbands itself right now.
===== RC2 : Prusa STL file =====
Here is a [https://github.com/makernexus/prusa-covid19-shield-remix/raw/master/plate-full-of-bottom-supports.3mf plate-full-of-bottom-supports.3mf] file to load directly into a slicer. Sometimes it is
Pre-arranged to print 2 at one time.
a good idea to use the night-time shift to print these.
* [[:media:covid19_headband_rc2_2x.stl|Prusa RC2 (x2)]] STL File
For other arrangements, here's the [https://www.prusaprinters.org/prints/25857-protective-face-shield-rc1 original Prusa design page].


====== G-codes ======
Direct gcode files for common printers (WIP):
* Prusa MK3S (Right click and select "Save link as". Then save as type ".gcode" -- instead of .txt -- before printing!):
** [[:media:CovidShield_RC2_2x_0.25mm_PETG_MK3S_6h17m.gcode.txt| RC2(x2) / PETG]]
** [[:media:CovidShield_RC2_2x_0.25mm_PLA_MK3S_5h56m.gcode.txt| RC2(x2) / PLA]]


===== RC1 : Older Prusa STL file =====
More files, 3mf and STL you get directly on Github: https://github.com/makernexus/prusa-covid19-shield-remix#cut-to-the-chase-gcode-ready-to-use
Pre-arranged to print 3 at one time.
* [[:media:COVID19 SHIELD R1 3x.stl|Prusa RC1 (x3)]]  STL File
For other arrangements, here's the [https://www.prusaprinters.org/prints/25857-protective-face-shield-rc1 original Prusa design page].


== Laser Cut Parts ==
== Laser Cut Parts ==


* [[:media:Faceshield-laser.svg|The SVG file for laser cutting the shield part]] SVG File
* [[:media:Wrapover-faceshield-laser.svg|The SVG file for laser cutting the shield part]] SVG File
* [[:media:X4 020PETG raw.svg|The SVG file but 4 at a time]].
 
The shields are cut from 0.020 inch thick PETG sheets.  We have successfully used 0.030, it is more expensive. 0.040 is too thick and will not snap onto the headband.


The shields are cut from 0.020 inch thick PETG sheets. Our base design fits into sheets of 24"x32". If we get donations of larger sheets, then we cut it down before using it.
'''PETG Sheet'''
 
One 4x8 foot sheet can make 24 shields. Our base design fits into sheets of 24"x32". If we get donations of larger sheets, then we cut it down before using it. Sheets come in different thicknesses.
 
* .020 inch CLR VIVAK PETG JFM is the best. This typically comes with a protective skin on each side.
* .015 inch PETG can be used. It often comes without the protective skins, so you will have laser cutter residue on the shield.
* .030 inch PETG can be used with 3D printed headbands. However, for injection molded parts the shield holes have to be modified slightly or the shield will pull too flat.
 
We believe both APET and RPET can also be used.


== Elastic Band ==
== Elastic Band ==
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* [https://www.homesew.com/ Home Sew]
* [https://www.homesew.com/ Home Sew]


== Assembly ==
== Assembly and Disassembly ==
 
Each box of face shields contains a QR Code that links to [[Covid-19 Shield User Instructions]]
 
'''Assembly'''


Assembly requires about 8" of 3/4 wide button hole elastic.
Assembly requires about 8" of 3/4 wide button hole elastic.
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* A short video on [https://youtu.be/qKqDUExM4Q8 how to assemble the Maker Nexus face shield version RC2]
* A short video on [https://youtu.be/qKqDUExM4Q8 how to assemble the Maker Nexus face shield version RC2]


* The original design [https://www.prusaprinters.org/prints/25857-prusa-protective-face-shield-rc2 Prusa RC2 STL- On this page]
* A nice graphic [https://www.covidshieldnexus.org/faceshieldassembly on assembly] also here [[media:Faceshieldassembly_v01.pdf|PDF]]


== Disassembly for cleaning ==
'''Disassembly for cleaning'''


These face shields can be taken apart for cleaning.  
These face shields can be taken apart for cleaning.  
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A short video on [https://www.youtube.com/watch?v=F7FFPzGeRME how to take the Maker Nexus face shield apart]
A short video on [https://www.youtube.com/watch?v=F7FFPzGeRME how to take the Maker Nexus face shield apart]
== Help at MN ==
At this time we do not need volunteers in the makerspace itself. The space is on lockdown so that we do not introduce the virus into our work area.
=== Donations Needed ===
* PETG filament is useful - if you aren't able to print yourself. Any color in both 1.75mm and 3mm diameter filament. It should be in a factory sealed box or in a bag with desiccant.
* 3/4"-1" button hole elastic
* 0.020" thick PETG film for disposable masks, sheets or rolls
You can drop-off the donations at Maker Nexus, just leave it in the box by the front door of Maker Nexus.  Please use appropriate procedures when packaging - including wearing a new pair of gloves and a face mask if available. 
You can also donate via PayPal towards COVID-19 efforts that Maker Nexus is working on. [http://www.makernexus.org/donate Donate via Paypal] to support COVID-19 response efforts by Maker Nexus.
=== Who to contact ===
MN members join the #covid-faceshield channel on [https://www.makernexus.com/member-dashboard Slack]
If you don't have access to Slack, please email [mailto:faceshields@makernexus.org faceshields@makernexus.org]


== External Links ==
== External Links ==
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== Status ==
== Other Alternatives ==
=== Capacity ===
* 5 Prusa 3D printers
** 1.75mm PETG
** each can make 8 shields a day
* 4 other type
** 3mm PETG
** each can make 3 a day
* 4 other type 2
** 3mm PETG
** each can make 3 a day
* Remote print capability
** What is our current capacity in the community? We are working that out now - so many people are volunteering!
* 3 Laser cutters
** The shields cut quickly and we are only limited by material sourcing
* Assembly is very quick, we can easily keep up


=== Supplies ===
We sincerely hope that all health care workers get the PPE that they need. However, in some parts of the world this may not happen. We believe the design we are using is the best for our team to make. There are, however, other solutions and we will list some here.
As of 3/23/2020 1:15PM
* We have 1.75mm PETG reels to last through this week
* We are out of 3mm PETG and have more on order
* By the end of the day we will have enough PETG sheeting to make about 4,500 face shields
* We have 30 yards of button hole elastic, only enough for 135 face shields.


===Summary===
* [https://twitter.com/sanjayjaindc/status/1247883812249296898 Low end] for complete emergency use. Tape, sticks, and a sheet protector.
* If we have enough material we can make at least 65 face shields a day as of 3/23/2020.
* [https://3dprint.nih.gov/discover/face-shield NIH exchange] has a number of different designs
* We currently have about 85 ready to be assembled (3/23/2020 1:15pm)
* The original design [https://www.prusaprinters.org/prints/25857-prusa-protective-face-shield-rc2 Prusa RC2 STL- On this page]
** We are waiting for final approval on the actual shield design from our health care provider partner.
* [https://www.notion.so/Open-Source-Face-Shield-c7ebd84f2dbe4be5ab0974c85c49d9ff A design using only a laser cutter]

Latest revision as of 23:54, 29 January 2021

Dr. Sanjay Kurani of VMC with Maker Nexus face shield
Regional Medical Center San Jose with MN face shields

Face shields are used by health care professionals to protect them when working with patients. Hospital supplies were running low. While they prefer to use commercially manufactured ones, in this emergency they were looking for alternative sources.

Visit COVID Shield Nexus for additional information on the overall program.

Overview

Front View
Side View
Top View showing wrap over

Maker Nexus has wrapped up our efforts on this project. With the help of over 600 volunteers around the country (and Canada) we have made and given away over 80,000 face shields. We also partnered with a local philanthropic company to make and give away 170,000 more. Over 250,000 face shields in total from this project! Other groups are still working on face shields. If you want to get involved you should contact them.

The headband portion of these shields is made on a 3D printer. If you have a 3D printer, you can make these. We delivered them to local hospitals.

In the News

Our press kit

How much do they cost?

​We gave these away, paying for them from donations. We did not sell them. Promises of donations or actual donations did not affect who was prioritized to receive the PPE. The allocation team was not told who has donated. However, they cost us about $5 each to make. Donations were critical for us to be able to keep producing. We were pleased that so many donated to support the effort. ​ Was there really a need?

  • We heard from friends that "nurses are cutting up plastic soda bottles to make face shields, using saran wrap on top of N95 masks to allow for multi-use."
  • One local nurse said they are making face shields from cut up shower curtains and hot glue guns.
  • In reviewing the current design: "The nurses were over the moon about how easily the shields can be disassembled and sterilized."
  • A nurse from Marin called us and I got her hooked into the allocation process and told her they were free. She started crying on the phone. - JimS

Some photos of front line workers with Maker Nexus face shields.

See stories from those who have received face shields from us.


How do I get some?

We stopped our efforts because there are now shields available from many retail outlets. Do a web search on "face shields".

If you need them for free, you could contact one of the following organizations:

A link to Other COVID Projects

3D Print Parts At Home

Use Your 3D Printer for good

Maker Nexus has ended this project. We appreciate all the work the distributed team has done. With your help we have been able to make and give away over 250,000 face shields across the US.

3D Print Directions

Materials

Filament

These face shields are best done with PETG filament. A 1kg spool can make about 20 units. They can be done with PLA but it is difficult to get them strong enough to handle all the bending.

The face shield stiffener at the bottom of the plastic shield can be printed in PLA. A 1kg spool can make about 180 units.

Instructions

Printer Settings

Print with PETG for ease of sanitation - IPA, Hydrogen Peroxide, Bleach, and Acetic Acid up to 10% can all be safely used with PETG. If you don't have PETG, using ABS and PLA is also an approved option.

Print settings:

  • Temperature based on filament selection.
  • 3 perimeters
  • 100% infill
  • 0.3mm Draft settings in PrusaSlicer work fine
  • we are running our Prusa's at 130% speed

Parts

We use a modified Prusa design. Our headbands maintain compatibility with the placement of the pins to mount the shield. After consultation with two local hospital teams, we made several changes to the original Prusa design.

  • The shield mounting pins are moved up to the middle of the headband to eliminate a potential entry point for aerosols. When the shield is mounted to lower pins the hole in the shield is not completely covered by the headband.
  • The flex points between the headband and the "wings" have a radius added. This makes it easier to clean. The original design had a narrow angle in that area.
  • The headband is made narrower to print faster. We find that using PETG these headbands are very strong.
  • The shield has an over-the-top dome that protects against droplets falling down onto the face.

Our design is, of course, released back to the world under the same CC licensing as the original. Links to our design files are on this page.

What to print now

Please do not print additional parts for us.

Historic

Files for the parts we used to make our face shields

Bottom Stiffeners

Prusa-bottom-part-plate.png

On one build-plate of a Prusa, we are able to fit 34 (might be a little bit more with more squeezing); it takes a little bit more than 8 hours, which is great for night-shifts, as there is no lost time. This also means that in optimal situations, we can get around 100 per day per printer.

GCode:


Head bands

Most important change in our headband design is that the pins are centered in the headband, so that there is something covering the shield punch, making a better seal. Also, the radii in the crevices are larger than the original to facilitate easier sanitation.

Latest release is v1.9 (2020-04-06)

This archive contains (next to the source files) the following files used used to print, which you also can download here:

  • Ready-to-go GCode: T9-PETG-Prusa.gcode (right click, download or save link as...) for PETG, T9-PLA-Prusa.gcode for PLA. This prints two headbands and two bottom stabilizers. Using print-speed of 130% on the Prusa seems to work fine. If you use ABS, please use the files below to slice for your printer. These print with little 'D-shaped' supports in front of the pins, that should break off easily.
  • 3MF slicer project file thin_shield.3mf for PETG and thin_pla_shield.3mf for PLA. This allows you to choose placement, temperatures, select which parts to print on the bed etc.
  • slice yourself thin_shield_with_support.stl (right click, download or save link as...) for PETG, thin_pla_shield_with_support.stl for PLA. There is also a no-support stl version in case you want to add support for the front-pins yourself in your slicer. If you _do_ print with build-in supports, make sure to enable the 'Detect Thin Walls' feature in your slicer.

Also please print one bottom_reinforcement.stl per headband (sometimes it is more efficient to do that separately). If you slice the version with built-in support, make sure to have 'enable thin wall detection' in your slicer. The 3mf files already have that enabled.

If your printer can't fit a headband, you can still help and print the bottom parts, stabilizing the shield plastic: Print as many bottom_reinforcement.stl that you fit on your print-bed: we need them as many people with larger print-beds focus on the headbands itself right now. Here is a plate-full-of-bottom-supports.3mf file to load directly into a slicer. Sometimes it is a good idea to use the night-time shift to print these.


More files, 3mf and STL you get directly on Github: https://github.com/makernexus/prusa-covid19-shield-remix#cut-to-the-chase-gcode-ready-to-use

Laser Cut Parts

The shields are cut from 0.020 inch thick PETG sheets. We have successfully used 0.030, it is more expensive. 0.040 is too thick and will not snap onto the headband.

PETG Sheet

One 4x8 foot sheet can make 24 shields. Our base design fits into sheets of 24"x32". If we get donations of larger sheets, then we cut it down before using it. Sheets come in different thicknesses.

  • .020 inch CLR VIVAK PETG JFM is the best. This typically comes with a protective skin on each side.
  • .015 inch PETG can be used. It often comes without the protective skins, so you will have laser cutter residue on the shield.
  • .030 inch PETG can be used with 3D printed headbands. However, for injection molded parts the shield holes have to be modified slightly or the shield will pull too flat.

We believe both APET and RPET can also be used.

Elastic Band

Each shield uses approximately 8 inches of button hole elastic, 3/4 inch wide.

Sources

Assembly and Disassembly

Each box of face shields contains a QR Code that links to Covid-19 Shield User Instructions

Assembly

Assembly requires about 8" of 3/4 wide button hole elastic.

Disassembly for cleaning

These face shields can be taken apart for cleaning.

The sheets are made of PETG and can handle alcohol and UV. The head band and spreader could be made of PETG, ABS, or PLA. These all resist alcohol but are heat sensitive. We are not experts in how to sanitize equipment. You, as user, take responsibility for appropriate sanitization. See this page from Prusa Research for information on sanitization methods currently being tested.

A short video on how to take the Maker Nexus face shield apart

External Links

Information & Discussions

- External slack for Prusa Shield discussions


Other Alternatives

We sincerely hope that all health care workers get the PPE that they need. However, in some parts of the world this may not happen. We believe the design we are using is the best for our team to make. There are, however, other solutions and we will list some here.

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