DIY PPE Ear Saver (3D Printer Not Needed)

With the increased need for PPE to battle COVID19 I was seeing a lot of 3D printed Ear Savers for holding the elastics on surgical masks off the ears of those wearing them for long periods of time.

Again, not too many made from viable found materials that the average person could make at home. So with another quick trip to the hardware store, more Hanger Strap, and Cable Ties (provided by Nelco), I've been able to engineer and prove that it is possible to make a DIY Ear Saver. I've tried to make the prep and assembly as quick/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 5 Straps in roughly 5 minutes.

Like my Face Shields, these are really simple. I've chosen materials, due to my professional background, that can withstand UV exposure or Alcohol/Peroxide dipping or spraying. You can use left over Hanger strap from making My Face Shields if the pieces are long enough. So very little is being wasted.

Please inform your hospitals or staff that they can be cleaned/sterilized or thrown away if needed.

Supplies

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)

*Note: 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).

Step 1: TOOLS NEEDED

Wire or Hobby Flush Cutters

Scissors

Ruler or Measuring Devise (not shown)

Step 2: PREP WORK AREA - BE CLEAN

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 straps upon receiving. A good practice is to always work as if you are sick and don't want to pass anything on.

Step 3: MAKING THE STRAP (EAR SAVER)

1. Cut a Piece of Plastic Hanger Strap to the length of 8 Inches (20.32 cm) This measurement should give you 10 Dot/Holes between each end.

*Note: 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).

2. Trim each end as indicated to round them off.

Step 4: FORMING THE ELASTIC HOOKS

1. Fold over 1 end so the hole lines up with the next. (Please reference the images included).

2. Send a Zip Tie through the back side of the Strap so it goes through both holes to the out side.

3. Fasten and secure the Zip Tie and pull flat. Be sure to check the alinement of the Zip Tie so it looks like the reference images. You don't want the locking piece of the Zip Tie to be on the inside of the Strap where it will press into the wearer.

4. Trim the Zip Tie flush

5. Repeat 1- 4 for the other end.

Step 5: You Now Have a Completed Ear Saver.

1. Hook the Elastic of your Mask around the Hook/Tab you've made by folding over the end.

2. Now Wear the Mask for long periods of time, more comfortably.

* Please note that these Straps, due to their size, can be dropped into a container of Peroxide or Alcohol to be sure they are clean before delivery.

Comments

[weibbed]

I cut a plastic milk carton into approx. 1-1/2" wide strips as long as possible, rounded the ends, cut rounded notches about an inch in from each end. Folded the strip at the notches. Wear by putting elastic over one fold, folded side towards the head, and repeat on the other side. Easy to make, disposable after each use, and customizable length for comfort.

[apinklady18]

Thank you so much for sharing

[RobertaY1]

I’ve made 36 of these from a 3/4 X 25’ roll in case anyone is interested in how many you can make. I also discovered that if you have size 24 plastic snaps you can use those in place of the cable ties. However, you will probably get less out of each roll if you do that.

[GimmeBuilds]

This is interesting. I was wondering if snaps would also work. My only thought with using plastic snaps was with repeated use will they stay snapped and keep the end folded over to make the hook section? Also Price was my biggest concern as well for individuals. For about $5 you can get 100 zip ties. How many snaps can you purchase with that? What does your final piece look like? Still curious. Thanks for this. Also if this is what you find works for you, run with it. I was hoping people would use this Instructable as a springboard for further development. Cheers.

[RobertaY1]

Finished with snaps.

[RobertaY1]

I think the design is most cost effective the way you designed it. The snaps cost about $8 per 100. And you use more of the strapping with snaps. Also, repeatedly folding the strap might make it weak. I’ll post a pic when I finish it.

[jessyratfink]

Great solution :)

[GimmeBuilds]

Thank you! Hope you are well and staying safe. Cheers.

[KVSBUNNY]

Another great idea! Thank you!

[GimmeBuilds]

Again very welcome. My goal was to give everyone the encouragement to realize that they can help in some way.