Face Shield

Introduction: Face Shield

The purpose of a face shield is to protect the user's face from hazards. In this project, you will learn how to make a face shield using a hard hat, plastic, and plexiglass.


The supplies you will need for this project include:

  • At least a 9"x12" piece of plexiglass
  • A medium-large hard-plastic bucket
  • A hard hat
  • 6 M5 1/4" bolts with 6 nuts and 12 washers

The tools needed for this project include:

  • Band Saw
  • Drill Press
  • C-Clamps
  • Hand Sander
  • Belt Sander
  • Sanding Block
  • Utility Knife
  • Heat Gun

Step 1: Cutting and Shaping the Plexiglass


  1. Measure a 9"x12" rectangle of plexiglass
  2. Score the edges of the rectangle
  3. Break along the edges
  4. Sand edges using a hand sander
  5. Mark bottom edges (on the 12" side) using a rounded surface (I used a can of spray paint)
  6. Cut rounded part using a band saw
  7. Sand the rounded edges using a belt sander
  8. Sand all edges using a block sander
  9. Take off plastic on the plexiglass
  10. Bake plexiglass in oven at 300 degrees for about 7 minutes (place on aluminum foil)
  11. Shape the plexiglass (I used an 8" diameter cardboard tube) make sure to use potholders so as not to texture the plexiglass
  12. If there are any imperfections, use a heat gun to smooth them out

Step 2: Cutting the Plastic


  1. Square off one edge of the plastic
  2. Measure 1" from the straight edge
  3. Cut on the 1" line
  4. Cut the ends of the strip
  5. On a separate piece of plastic, cut a 1.5" thick strip
  6. Square off one end
  7. Cut two 2.25" strips from the 1.5" thick plastic
  8. Measure a 1.5"x1.5" square on the strips, underneath it measure a 30mm thick tab
  9. Cut off the excess on the sides of the 30mm tab using a band saw
  10. Sand the edges of the tabs so that they fit into the slots on the hard hat
  11. Measure 25" of the 1" thick strip
  12. Cut off the excess
  13. Find the center of the 1.5"x1.5" squares
  14. Drill a hole in the center of each

Step 3: Attaching the Plexiglass to the Plastic Strip


  1. Using some extra plastic, drill a hole 1/2" from the edge
  2. Drill another hole 3 2/3" from the first hole
  3. Put dots on the plexiglass where the template holes are (you should have 4 dots when finished)
  4. Drill the first hole in the plexiglass and the 1" thick strip of plastic
  5. Use a nut, two washers, and a bolt to attach the glass to the plastic
    • Note: one washer should be against the outside of the plastic and one should be on the outside of the plexiglass, so that the order is bolt-washer-plastic-glass-washer-nut
  6. Drill the remaining holes through the plexiglass and plastic at the same time
  7. Repeat step 5 three more times
  8. Cut off the extra plastic, leaving about 3.5" on each side of the face shield

Step 4: Attaching the Plastic Strip to the Tabs


  1. Drill holes in each end of the 1" thick plastic strip, 1/2" from the end
  2. Use a nut, two washers, and a bolt to attach the tabs
    • The tabs should be on the outside, so the order is bolt-washer-tab-strip-washer-nut
  3. Tighten the nuts as much as possible so that the face shield doesn't slip
First Time Author Contest

Participated in the
First Time Author Contest

Be the First to Share


    • Summer Fun: Student Design Challenge

      Summer Fun: Student Design Challenge
    • Make it Fly Challenge

      Make it Fly Challenge
    • Fruit and Veggies Speed Challenge

      Fruit and Veggies Speed Challenge