COVID-19 DIY Reusable Face Shield

This is a how-to guide on how to make your own face shield to be used in hospitals when treating patients with COVID-19. This face shield is autoclavable/sterilizable and, therefore, reusable. The face shield includes an adjustable strap to ensure it fits on all individuals. It also includes a curved bottom to maximize protection from all angles. The materials needed to create this face shield are as follows:

24” x 24” Polycarbonate Sheet(or large enough to have a 12” x 12”)

Scissors or Knife/Cutting Tool

Printer (for printing template)

Paper (for printing template)

Non-Latex Rubber Foam Roll

3M Double-Sided Tape

Stainless Steel Snaps (4) (Stainless steel snaps will not rust easily but are not the best quality, note that you may need to find a different brand of stainless steel snaps)

Anvil & Flaring Tool (For a fully autoclavable face shield, DO NOT use the snaps that come in this set. Instead, use the stainless steel snaps from the link above)

Hammer

Sealing Tape

Polypropylene Velcro Cinch Straps (2)

Take your 12” x 48” polycarbonate sheet and cut it into 12” x 12” sheets

Do NOT take off protective film of either side of the plastic sheet

Print the “Printed Template.docx”. Fold and tape into a 12” x 12” square. The lines from each page should be slightly overlapped (taping the lines end-to-end will result in a square larger than 12” x 12”)

This is going to be the template used for marking the cuts and placement of the foam. It should look like the “Face Shield Template.jpg”, shown below.

Place your polycarbonate sheet over the template and using a dry erase marker, trace the marks from the template onto your polycarbonate sheet.

The black line indicates the outer edge of your polycarbonate sheets. Cut along the red and purple lines of the template.

The green rectangle indicates where the foam spacer will be placed later on. Do not cut this rectangle.

Using a hole puncher, punch a hole on the center of the orange circles onto the polycarbonate sheet. If no hole puncher is available, use a knife or scissors to cut small X’s in the center of the orange circles.

Your plastic sheet should look like the image above.

Take your foam roll and cut five pieces of 1.5” x 6” strips

Take the double-sided 3M tape sheet and cut five pieces of 1.5” x 6” strips

Take the tape and foam on top of each other, alternating between the foam and tape for each layer.

Be sure to remove the film on both sides of the 3M tape to be double-sided, except for the last piece.

You should end up with an extra piece of tape with a protective film on one side which will be used to attach the foam spacer onto the polycarbonate sheet in the green rectangle later on.
Do NOT attach onto the plastic sheet yet!

Remove the protective film on the side WITHOUT the template markings.

You should still have the template markings on the protective film with your plastic sheet after this step.

Remove the protective film on 3M tape of the foam spacer and place it into the green rectangle outline on the polycarbonate sheet on the side without its protective film.

Remove the protective film on the other side of the polycarbonate sheet.

Your plastic sheet should now be clear and completely transparent

With the foam-side up, place a button/cap under one of the holes in the center portion of the polycarbonate sheet.

Place the anvil (smooth-side up) under the cap and place the socket over the polycarbonate sheet in the center of the cap.

Using a hammer and flaring tool, secure the socket to the cap.

Repeat steps 12 and 13 for the remaining 3 holes in the center portion.

Flip the polycarbonate sheet over so it is foam-side down and flip the anvil over so the patterned side is facing up.

Place the eyelet/post under the plastic sheet and on top of the anvil on one of the remaining holes.

On the same hole, place the stud over the plastic sheet in the center of the eyelet.

Using a hammer and flaring tool, secure the stud to the eyelet.

Repeat step 15 for the remaining holes on the left and right side of the polycarbonate sheet.

Fold the side pieces over the middle flap and secure the snaps together as shown.

When using the stainless steel snaps, it may take extra pressure to fasten the snaps. You may need to hammer the snaps more to ensure that they will fasten properly.

Cut two pieces of sealing tape (about 3.25” long) and tape over the edges as shown.

Using the slits next to the foam spacer, place the two cinch straps through the slits as shown in the pictures.

Attach/connect the cinch straps together in the front of the face shield.

The face shield is now ready to be placed on the user’s face and adjusted to their liking.