Introduction: DIY Rc2 Visor and Face Shields

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Headband for Simple Face Shield Assembly

Why is this needed?

Face shields are personal protective equipment used to help prevent droplets of contaminated fluids from reaching the user’s face. This band can be quickly made to hold a plastic face shield visor in place and secured to the user. These instructions include the headband, jig for cutting the plastic shield, and affixing instructions. Instructions show how to make up to 100 plastic shields at a time

How is this used?

The face shield band is attached to the clear visor and affixed atop the user’s head.

How is this sanitized?

Follow this link for disinfection information


Supplies Needed Include:

3D printer

PLA / PLA+ filament

One-hundred 8.5" x 11" projector transparencies

Two 8.5" x 11" x 3/16" aluminum plates

Drill with 1/4" drill bit

Four c-clamps

Belt Grinder

Step 1: Print the Headband

This is the .stl file for the headband. We will get back to this at the end, for now just use these settings and ensure that the print is perfect, no defects. It is imperative that the print be defect free to ensure viability.

Layer Height: 0.2mm

Perimieters: 3

Infill: 30%

Infill Type: Honeycomb

Top/Bottom layers: 4

Seam Position: Nearest/Random

Extruder Temperature: 215 - 220 C

No Supports, No Brim, No raft or anything that would produce sharp defects.

Please ensure that the first layer is not over extruded as it produces a sharp edge.

Step 2: Print the Template Tool

This is the tool that will help you align the drill holes in the visors. Use the same print settings as the headband.

Step 3: Making the Shields Step 1

Gather your 8.5" x 11" transparencies.

Step 4: Making the Shields Step 2

Gather your 8.5" x 11" x 3/16" aluminum plates, marked and centerpunched using your Prusa RC2 template.

Drill out using standard 1/4" drill bit. Radius the edges when you're done to remove burrs.

Step 5: Making the Shields Step 3

Take up to 500 sheets of 2 mil transparencies, stack them up while in their bags, and clamp between plates with four C-clamps. Be sure to keep everything as square as possible. Light taps with a ball peen can "persuade" the sheets.

When all of the sheets are square, drill through the pre-drilled holes in the aluminum sheets.

Step 6: Making the Shields Step 4

Grind edges of transparencies off while they are clamped using a belt sander/grinder. It will get melt-y, don't worry! It keeps all the pages together when you're done!

Step 7: Affixing Visor to Headband

Attach the plastic visors to the headband by placing pushing the holes onto the pegs in the front of the headband.

Step 8: Adjusting Headband for Your Head

This video shows how to get a better fit for the headband.

YouTube Link