DIY PPE Face Shield (3D Printer Not Needed)

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Introduction: DIY PPE Face Shield (3D Printer Not Needed)

About: Gimme Builds - I'm a professionally trained Toy/Product Designer. Another huge fan of LEGO, MOCs & Making! Let’s share Ideas & Builds. That’s what makes life fun. Call me Zac, all my friends and family…

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.

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)

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.

Step 1: TOOLS NEEDED

Awl (or Large Nail)

Wire or Hobby Flush Cutters

Scissors

Office Hole Punch ( Or Leather Hole Punch)

Black Marker or Pen

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 shields 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 HEAD BAND

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

Step 4: ROUND HEAD BAND ENDS

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.

Step 5: ASSEMBLE THE HEAD BAND

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.

Step 6: PREPARE & INSTALL THE ELASTIC

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.

Step 7: PREPARE THE CLEAR PLASTIC COVER

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.

Step 8: ATTACH THE CLEAR PLASTIC COVER

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

Step 9: Your DIY Face Shield Is Complete!

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.

Step 10: SUGGESTIONS FOR MAKING FASTER

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!

1 Person Made This Project!

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39 Comments

0
DavidvE10
DavidvE10

8 months ago

I purchased the CRC 52309 report cover sheets from Fellowes but I found them not to be completely clear. Did you find that as well or are they different from the ones you used? Otherwise the design is great.

0
lcwarren6
lcwarren6

Tip 11 months ago

Wonderful design, thank you! I made some modifications to accommodate the large loupes and head lights that many dentists and dental hygienists wear. I also attached the clear sheet to the inside of the halo to make it look a little more polished :)

IMG_20200517_161132.jpg
0
GimmeBuilds
GimmeBuilds

Reply 11 months ago

So glad they are working for everyone even if you have to mod or use other found materials. That was my goal. Cheers

0
GimmeBuilds
GimmeBuilds

Reply 11 months ago

That's Great! Thank you for sharing.

1
kissymoose
kissymoose

11 months ago

I have so much to share! But THANK YOU should come 1st!
THANK YOU Zac!
I have a dad in a Veterans Home ran by VA here in WA state. I made some of these face shields AND did some 3d printed "Snap-n-go" face shield visors for the staff there. Staff count is about 180 persons and there are 80 residents, 1 being my Vet dad.

So far there are ZERO, repeat, ZERO Covid-19 bugs! The staff are vigilant!

So I made your version and the 3d printed version. I figured they'd use your version as an absolute last resort (911 type) back up. And use the 3d printed versions daily. Was I wrong! LOL, they want MORE of your version.

I originally sent them about 140 shields with laminates. So then, I get an email from Olympia saying they'd like your version for all 4 of their state VA (nursing) Homes!!
I will be supplying your face shields for our "Heroes Caring for Our Warriors"!!!
So THANK YOU for such a simplistic PPE (and self sufficient PPE as we can purchase local supplies)!!

I'd like to add that I, too, have modified it a little: Pics attached

1. Use rubber band instead of hair tie. Use tie wraps to secure rubber band. (It seems that most medical facilities already procure rubber bands and laminate sheets, so why not use what they can already get!)

2. I added a strip of thin foam at forehead for sweat as it helps to keep the shield from sliding around while sweaty. (We have temps here over 100+ during summer!)

3. I added some fun "emoji" stickers to help "relieve" the Covid stress of wearing these things! We have WAR Veterans looking at the staff wearing these all day which tends to bring out the PTSD on both sides of the face shield!! So why not make it more "fun". I am working on "blinging" them up and find things that staff can pick from to allow them to "be creative" and add a bit of personality to their PPE! ( Little Googly Eyes being attached next! LOL)

This is a good place to remind everyone that these HAVE to be sanitized regularly, and suggesting to use a spray bottle with alcohol in it seems to get to ALL of the cracks & crevices, where wiping with a handi wipe may not. So be sure, if you BLING them up, to use stuff that will stand up to alcohol. I figure the stickers can be replaced when faded. I will be checking other things like "Jibbitz" and sticky back jewels, etc. :0)

You will be amazed to know that like the others have said, our Veterans Home said these were FAR BETTER than what their Government suppliers are sending (they are the ones with just the foam forehead stuck to a piece of laminate with a string of elastic, which dumbfounds me)!!
I am in the process of purchasing MORE strap, foam & cable ties from Amazon (decent price to me for easy shopping! I will add those links below).

I will be building about 700 MORE face shield "visors" to support 4 of our Veterans Homes here in our state!
ALL 4!! They want YOUR design over the ones sent to them! (I'm sure I will be making more to keep them all in stock of face shields!)

I am sure to credit YOU for the design as you deserve the recognition for coming up with the most simplistic AND self sufficient design! They REALLY WORK well. I do like the other commenter who redesigned it for wearing loupes. I will be sure to send that photo along with the "end of instructions" that I made, with your instructions help, about mounting the laminate!

NOTES:
I can get about:

Qty: 35 Face Shield "Visors" from 1 roll of 100ft Hanger Strap (at 2 strips per face shield)

Qty: 240 Foam Headband strips at about 5 inches long each

Qty: 10-12 tie wraps per face shield. Using 2 tie wraps for Rubber Band, 2 tie wraps for headband, and 2 tie wraps for laminate. I send extra tie wraps so that multiple laminates can be used & disposed of, but keep the same headband.

Using a 3 inch Rubber band stretches about twice that length, and it can be shortened using the tie wrap. Seems this works great too as it is more sanitizable then the fabric wrapped bands. Most places already have rubber bands on hand, and a variety of sizes, so this should work for MY application. If you supply the rubber bands, just get a large bag of mixed sizes. You can always shorten the longer ones with tie wraps!

Also, tell your users that they should suggest using a sharpie to put their badge #, or Personnel ID (NOT their names!) on the headband, so if it gets lost or laying around, it can be identified! wink wink

Links:
Amazon:
Be careful, watch for the 100 FOOT roll, not the 25ft roll! More bang for your buck!
Oatey 33927 Securing Straps, 3/4" x 100', 3/4-Inch by 100-Foothttps://smile.amazon.com/gp/product/B00207OT30/ref=ox_sc_act_title_3?smid=ATVPDKIKX0DER&psc=1 Today it is $11.74 for 100ft roll


High Density Foam Tape, Seal Strip Self Adhesive Weather Stripping for Doors Seal and Window, Insulation Single Sided Foam Strips,2 Rolls(1/16"T,1"W, 50FT per roll) Won't let me put the link in?? But there is the title of the product.
Today it is $10.90 for a 2 pack of 50ft per roll. Total 100 ft.


TrendBox 2000 (Size: 3x80mm/3 inches) White Self-Locking Nylon Plastic Cable Cord Zip Ties Wrap Fasten Wire Durable Indoor Outdoor Travel Home Corrosion ResistanceAgain, you'll need to look these up on Amazon. I allow for about 10-12 tie wraps per visor/headband. Today they are $8.99 (for 2000!!)

This is my buying in bulk, you may not need as many, but hopefully the product names I am using will help everyone find what they need too.

For West Coasters:

A great source for Binding Covers 7 mil (laminate) is LaminationDepot.com. I had to order over $75 for free shipping, but no tax! They are on Amazon too, but I found that dealing with them directly was a great experience. They were out of what I wanted, called them up on a Friday, the gal was contacting the warehouse as we were chatting, she put my order in, they are in California, and I got my shipment on Monday! Awesome crew!

Price is $13.99 for box of 100 count (8.5" x 11")
https://www.laminationdepot.com/PVC-Clear-Binding-Covers-Qty-100?quantity=1&custcol_cover_thickness=2&custcol_cover_size=1&custcol_tissue=1

Last note on laminates:
DO NOT BUY "WATERPROOF" or "MATTE" as it has a milky haze to it.
Only buy "CLEAR"!
Also, if you buy "Laminate Pouches" then you have to run them through a Laminator or they won't work.
Like Zac suggested, I am using "Binding Covers", which are single sheets. Be sure to get at least a 7 mil, they are more rigid.

Again, THANKS SO MUCH ZAC!
This is an AMAZING Experience to share with you! :)
What a journey!

Thank YOU Zac for helping me to help our Heroes caring for our Warriors!
From KissyMoose in WA State!

IMG_20200522_224228133.jpgIMG_20200522_224739544.jpgDIY-PPE-Face-Shield-3D-Printer-Not-Needed-16.jpgFace Shield Kit sample.jpg
1
kissymoose
kissymoose

Reply 11 months ago

The Rubber band on the back, I think, stays in line with "K.I.S.S.".... Keep It Simple Silly! lol. Hey! It works! wink wink

0
ongjochewm
ongjochewm

1 year ago

Great idea! In trying out, however, I found that hair elastics in short supply and at 5.5 inches long, it made face shield band a bit on tight side for my head. Wife said same.

So it's either get shock cord (bungee line- 1/8 inch seems ideal as it fits in hole in plastic hanger strap) and cut to longer length (say 8 inches)) or make face strap larger (say 24 or 26 holes vs. 22) so short hair elastic can be used comfortably.

Also, I tried drilling holes thru cover binder sheet pack of 100 instead of doing all the work of hole punching. Worked but drill bit apparently would melt some of plastic which then quickly dried, leaving a plastic residue that had to be physically removed from the sheets.

0
GimmeBuilds
GimmeBuilds

Reply 11 months ago

I've been using the large or medium sized hair ties which seem to be plenty long enough. No complaints yet. The smaller hair ties that are about an 1/8 inch in diameter I wouldn't suggest simply because I found them too tight myself. Yes they do insert into the hole with out enlarging but gain just too tight. Thanks for sharing your experience in making these.

0
superuserbk
superuserbk

11 months ago

Thanks very nice video would like to modify with plastic caps instead of tie wraps to secure frame and sheet any suggestions on where to buy caps?

0
GimmeBuilds
GimmeBuilds

Reply 11 months ago

I've looked into plastic snaps and for the number you can get for the price it just isn't worth it in my case. Sorry I can't suggest any suppliers at the moment. If I come across any I will be sure to share. Thanks

0
princess barmcake
princess barmcake

Question 1 year ago on Introduction

HI, this is a fantastic tutorial, I cannot find the strap in the UK, any chance you could add in cm's or inches the length of the two pieces you cut? Im looking for a solid strap that I might be able to just put holes in myself.Thanks

0
GimmeBuilds
GimmeBuilds

Reply 1 year ago

Thank you for your support! I'm currently assembling dimensions and patterns to use as guides. What 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. I will be sure to update my intro with this info as well. I hope to have the Patterns up on the Instructable by the end of the day.

0
GimmeBuilds
GimmeBuilds

Reply 1 year ago

Thank you for the reply. Your all Plastic version looks ideal for reuse. The card stock version I can see as a 1time use. Great Job!

0
inomni
inomni

Tip 1 year ago

The Walmart Equate version of the elastic hair bands are a slightly smaller diameter, and the strap holes do not need to be enlarged. These fit through with no adapting. Thanks for the great tutorial!

IMG_9723.jpgIMG_9724.jpg
0
GimmeBuilds
GimmeBuilds

Reply 1 year ago

Thank you for that note. I've been using the medium sized Equate hair elastics, but if the smaller diameter elastics work just as well I will update the Instructions to speed up assembly. Thank you for passing along this info.

0
JCFiberArts
JCFiberArts

1 year ago

I have made 100+ for a skilled nursing facility near me and have been told these are more comfortable to wear than the ones obtained via medical supply co. Excellent pattern and instructions!

0
GimmeBuilds
GimmeBuilds

Reply 1 year ago

That's Fantastic! Would you mind sharing and tagging @GimmeBuilds on Twitter if you are there. This is great news!

0
yapingaling
yapingaling

1 year ago

Thank you so much for posting this!! Wondering if you’ve been able to test it long enough time know whether condensation/fogging is an issue or not? (If I make a big batch to donate I’d like to be able to answer the question if it comes up.) thank you!!

0
yapingaling
yapingaling

Reply 1 year ago

Awesome thank you so much for confirming that!!