DIY PPE Face Shield (3D Printer Not Needed)

With the increased need for PPE to battle COVID19 I was seeing a lot of 3D printed face shields being made, but not too many face shields made from viable found materials. So with a quick trip to the hardware store, office supply store, and the local retail, I've been able to engineer and prove with a field test that it is possible to make a DIY Face Shield. I've tried to make the prep and assembly as quick and easy as possible.

Now those with out 3D Printers can help in the battle.

On average, once the materials are prepped, I've been able to make 10 shields an hour. They are really simple to make.

I will leave suggestions for cutting down on assembly at the end, but let's focus on one for the moment.

I've chosen materials, due to my professional background, that can withstand UV exposure or Alcohol dipping or spraying. Please inform your hospitals or staff that they can be cleaned/sterilized or thrown away if needed.

UPDATE 04/08/2020 - I'm currently trying to source materials that are similar in Europe and will update this Instructable to suit those materials. For now though, the materials I'm referencing are found in the US (possibly Canada).

UPDATE 04/13/2020 - I've been able to find in Europe that would perform as a good substitute is Polypropylene (PP) Packing Strap, usually sold by shipping and mailing material suppliers. You would need to look for a 19mm wide PP strap/band. You would also need to use a leather punch to create the needed holes.

UPDATE 04/13/2020 - I've include printable patterns for Shield - Version 1 (No Upper Forehead Shield) Letter and A4 sized media. I'm still assembling the Upper Shield instructions, and thank you for your patience.

You Will Need:

Plastic Hanger Strap - roll/package of 3/4in (18.45mm) wide. (Found at Hard Ware supply usually with Plumbing)

Cable Ties - 4in (10.16cm) long - 5 for one shield. (Found at Hard Ware supply usually with Electrical)

Thick Hair Elastics - Large Hair Ties (Found at Retail usually with Hair Care Products)

Thick Clear Acetate Sheets - 8.5in x 11in - (I used 7mil Binding Covers for manuals and reports)

(Found at Retail and Office supply usually with folder and covers)

* Note: Don't use cloudy or fogged cover sheets they have to be clear.

** Others have used Laminating films for 3D printed Face Shields so if the thicker covers can't be found you can use the laminates instead.

Awl (or Large Nail)

Wire or Hobby Flush Cutters

Scissors

Office Hole Punch ( Or Leather Hole Punch)

Black Marker or Pen

Wash your hands and sanitize your work space. Try to keep your materials and tools as clean as possible.

For tools, wipe down with alcohol. If you can wear plastic gloves and a mask over your mouth and nose, please do so. If you are donating these to a Hospital they should have a way to sanitize the shields upon receiving. A good practice is to always work as if you are sick and don't want to pass anything on.

Take the Plastic Hanger strap and cut 2 pieces 22 dots long (as illustrated).

Trim/Flatten both ends of one of the straps you cut.

Then Round the Ends by cutting the corners in the pattern illustrated.

This will be the strap that comes in contact with skin, so we don't want any sharp corners.

1. Count from the End of the Rounded strap 4 Dots, and aline the 1st Dot from the other strap with the 4th dot.

2. Overlay the straps so the dots aline and send a Zip Tie through the 5th dot and back through 4th (as illustrated). This will hold the 2 straps together. Repeat for the other side.

3. With the Wire or Flush Cutters, trim off the Zip Ties.

4. Your bands should look like the last picture when attached to each other.

1. Take 1 Elastic Band and cut it so it no longer forms a loop. The best place is where the ends were joined during manufacturing.

2. Make a knot at one end of the Elastic, about 1in (2.5cm) from the end.

3. With the Awl or Large Nail, enlarge the last hole (dot) on the Head Band so that the elastic just fits through.
Push your Awl or Nail through the inside to the outside so there isn't a raised edge pressing against the wearers skin.

4. Pass the Elastic through the enlarged hole and then do the same for the other side.

5. Now with the elastic through both sides, tie off the other end with a knot 1in (2.5cm) from the end.

6. Your Head Band should look like the last picture. You are done assembling the Head Band.

* Note: Making the hole too big will allow the knot to pass through and then it won't work.

** Note: you can mark the depth of the Awl or Nail with tape wrapped around it as illustrated in the picture.

1. Cut a piece of Hanger Strap 16 dots long (as illustrated).

2. Place and Center the Strap on the Long Edge of the Clear Plastic Cover.

3. Move the Strap down about 1/8 in (4mm) from the edge of the Clear Plastic Cover.

4. Use the Marker to mark the Clear Plastic Cover through the holes in the strap.

5. Mark the 2nd and 3rd holes from each end and the Center 2 holes. You Clear Plastic Cover should look like the picture.

6. With your Hole Punch center each mark and punch a hole in that location.

7. Your Clear Plastic Cover should have 6 punched holes spaced as in the last picture.

1. Take the Head Band and count 3 Dots from the Zip Tie.

2. Overlap the Clear Plastic Cover so the first hole alines with the 3rd Dot on the Head Band.

3. Pass a Zip Tie through the Clear Plastic Cover and Head Band at the 3rd Hole and back out through the 4th Hole.

4. Secure the Zip Tie and Trim

5. Repeat 1 - 4 for the other side.

6. Pass a Zip Tie Through the 2 Center Holes of the Clear Plastic Cover and the alined holes of the Head Band.

7. Secure the Zip Tie and Trim

If you got this far in the build you should have a finished DIY Face Shield.

Please reach out to me if you have any questions regarding the steps or assembly, and I will try to talk you through any miss under standing. I will update this Instructable periodically with updates to the design. So please check back for updates.

I will eventually get to do a video assembly, thank you for your patients.

#StaySafe #FlattenTheCurve #HackThePandemic #MakerStrong

Good Luck Everyone!

* This DIY shield was used and tested in the field at Morristown and Chilton Medical Centers here in NJ.

1. Prep all your materials before assembling.

2. Once everything is prepped you can assemble them alone or with others to speed up the process.

3. Remember to practice social distancing if assembling with a group of people.

GOOD LUCK!