In order to help with the critical shortage of personal protective equipment (PPE) during the corona virus pandemic, we're making hundreds of face shields to give to first responders, nurses and doctors who are on the front lines.

We made a face shield from a piece of polycarbonate and a baseball cap. We geared up to making them by the hundreds but a simple one can be done with only a few tools, an old baseball hat and some plastic.

Here's the video of how to make one

https://youtu.be/grXbSme6kTY

Step 1: Supplies and Tools

Supplies:

- baseball cap

- piece of .03" polycarbonate*

- piece of cardboard or sheet metal to make template (if you're making lots of them)

Tools:

- tin snips

- utility knife

- sheet metal pliers or an aluminum block with a slot milled in it (for people making lots of them)

- pencil

* If you're making just one, plastic from prepackaged salad greens, soda bottle or laminating pouches can also work

Step 2: Marking the Hat

Cut out the template from sheet metal or cardboard. Then use a pencil to mark the hat in four places

Step 3: Cutting the Hat

Cut slits at the four pencil marks you just drew on the hat

Step 4: Fold Back the Brim

Fold back the brim on the hat using a sheet metal pliers (or anything else like a pliers, vise grips that works). Fold it back until it's at about 90 degrees to the brim. You want to fold about 1/2" or just about the length of the slits

If you have an aluminum block, just put the prim in about half an inch and fold it backwards. After removing the hat from the block, push with your thumbs so the brim is folded back just less than 90 degrees

Step 5: Cutting and Bending the Plastic

We cut our polycarbonate with a CNC router but if you're making just one, a scissors, utility knife or tin snips can work. Cut out the plastic according to the file included. And then cut the two slots near the top of the shield. Bend the plastic which helps hold the shield in the cap. We used a press brake but you can easily fold it by hand