Face shield

Face shield

Updated 04.09.20 at 13:00 PST

We have tried out two different versions of this shield:

  1. 3D Printed:  if you have access to a 3D printer, you can make a 3D printed frame – details of the design that has been clinically reviewed are here.  Note: learn how to donate your 3D printed visors to Seattle Makers so we can distribute them to the community and local health care professionals, here.
  2. EVA foam:  this version uses EVA foam to create space between the shield and your face – details here

If you live in the Seattle area, both options are available for free with a recommended donation – you just need to come pick them up while supplies last.

Shield + 3D printed frame

We have tried several iterations of a 3D printed frame for a face shield and have narrowed it down to this version with a visor.

IMPORTANT:  For individuals or organizations 3D printing face shields, please see this site on how to do it safely.

This design is now live on the NIH 3D print website here.  This design has undergone review in a clinical setting and is recommended when fabricated as instructed.  This to be the official CAD and STL file repository going forward.

The size of the design’s footprint on the printer bed is 201mm x 210mm.  You can optimize your print by using a 0.6mm head, increasing layer height to 0.35mm.  We don’t want to make too many other changes that could impact the tested and approved version.

If you’re interested in donating your 3D printed visors to Seattle Makers so we can distribute them to the community and local health care professionals, learn how here.

Shield + EVA foam

We have designed a face shield from mylar sheets, elastic, EVA foam, duct tape, and staples.

Update:  Our face shield design was not approved for medical use. We will be assembling our current stock and selling and distributing these to the community and organizations in need so we can recoup our costs and reduce the spread of disease. 

Let us know if you need a face shield, or know a hospital, grocery store, shelter, or other organization in need.  We will have them available for purchase in our online store shortly.

You can support us here. And here’s how to make them:

Materials

Mylar

The mylar sheets are sourced from TAP Plastics and can be ordered online from McMaster-Caar. The polyester film rolls are 40” wide, and come in 10- or 25-foot lengths. They can be purchased in .007 inch or .01 inch thickness.  Laser-cut to shape, either will work.

We cut our mylar with our Black Cat 90 Watt laser cutters.  The .svg file for the laser-cut mylar shield is here. The shield is 320mm wide x 215mm high. After breaking a few, we modified the slots for elastic for maximum strength (ovoid vs. square corners).  Square slots tore too easily when put under stress from the elastic band.

EVA foam

For the forehead cushion, EVA foam will create a comfortable seal against the forehead. The closed-cell EVA foam is much easier to sanitize than porous foam used in other models. You can get this at your local Harbor Freight, or order 24″ x 24″ interlocking EVA foam mats online.  We laser-cut 200mm x 35mm rectangles of EVA foam.  The file for a single rectangle is here, the file for a full sheet of 40 is here.  The full sheet file is 560mm x 560mm and fits on the usable portion of the 24″ x 24″ interlocking EVA foam mats.

Note:  When laser cutting 40 from a full sheet, we noticed that some of the cuts began to melt.  To give the material time to cool down, we cut all horizontal cuts first (in blue in the svg file) and then all vertical cuts (in red in the svg file).

Double-sided tape

We attach the EVA foam to the mylar using simple double-sided tape.  The tape is effective because it’s just holding the EVA in place when the wearer has taken the shield off.  When the wearer is wearing the shield, the elastic applies pressure between the EVA and the mylar, holding it in place.  A big shout out to Shari at ontimesupplies.com for expediting our shipment of tape.

Elastic

For the adjustable and, we have updated our design to reduce elastic use, and are now stapling 325mm lengths of elastic bands to either side of the mask, through duct tape reinforced corners.  We used a 1” knitted elastic band from Joann fabrics.  You can substitute for other bands, but we recommend ¾” or wider.  You may need to adjust the slots in the mylar if you change the size of the band. In a pinch you could also tie the mask to your head with shoelaces or twine.

Duct tape

We reinforced the corners of the mylar shield with duct tape where we stapled the elastic.  Without the duct tape, the staples tore the mylar.

Staples

We attached the elastic to the mylar shield with regular staples.

Assembly

Attaching the EVA foam to the shield
  1. Laser cut the mask out of mylar with the provided template (.svg file is here).
  2. Laser cut the EVA foam (single template .svg file is here, x40 template .svg file is here).
  3. Place the mylar mask on the table with the inside of the mask facing up, and the bottom of the mask toward you. You might want to weigh down the top corners to prevent it from curling up.
  4. Place the EVA foam down with the textured side up, and put two strips of double sided tape onto the EVA foam.
  5. Note: Other adhesives and/or glues could work, this was quick and easy and had plenty of hold strength for our needs. You can also buy EVA foam that comes in self-adhesive strips.
  6. Flip the EVA over sticky-side down, and line it up with the top of the mask.
  7. Holding the left and right sides, bend it down in the middle and stick it to the mask.
  8. Bring the mask up to the curved foam. Press firmly for 10 seconds.
Attaching the elastic to the shield

Watch the video on how to attach the elastic.  Written instructions are below.

  1. Measure 325 mm of elastic band and cut.
  2. Thread the elastic band from the back, through to the front of the mask. Pull it around the front, and thread back through the opposite side.
  3. Overlap the elastic and test to ensure a secure fit.
  4. Hold the elastic at the correct length and staple in place.