Introduction: Face Shield

During the COVID-19 Pandemic, medical staff has been in constant shortage of PPE (Personal Protective Equipment). This DIY face shield design can be improvised at home or can use the specially designed 3D printed hinge. Depending on what you have at home and how closely you want to follow my personal steps, the cost can range from 100% recycled to about $100 (outsourcing 3D printing can cost over $50, so for a cheap and faithful design a 3D printer is recommended)

*Shown above is the prototype model, omitting the 3D model and misting function.

Tools needed:

  1. Scissors
  2. Marker
  3. Knife
  4. Hole punch or drill
  5. Electrical tape
  6. (Optional) Glue


Supplies needed:

  1. Shield (any will work)
    1. Clear 2L bottle (the closer to a straight cylinder, the better)
    2. Acetate--expensive, yet preferred
    3. Plexiglass
  2. 3Dprinted hinge
  3. <1cm garden tubing
    1. Mister
    2. Barbed connectors/tees
  4. Straps
  5. Aluminum or Plastic Banding, hanging straps for piping works great
  6. Plastic Screws or Zipties
  7. Soap Bottle with pump

Step 1: Cut Shield Material

If you're using a 2 Liter Bottle, cut about 1/2 inch below the cap and 1-2 inches above the bottom of the bottle. Then, cut the bottle vertically and open it. Trim the bottle to your liking so that it can comfortably cover your face with around 2 inches of clearance around your forehead.

If you're using a sheet like acetate, start by cutting out a trapezoid shape, the longest side will go along your forehead so make sure the sheet can comfortably cover your face without restricting movement. Round off the corners and bevel either side of the longest side of the trapezoid so that it is level when bent around your head.

Step 2: Supports

Make your headband; this can be as simple as adding the hinge (make sure it is the hinge WITHOUT the crescent shape) to some of your supportive banding and putting foam on the other side, or sandwiching your straps between the foam and hinge part with adhesive or plastic screws. Attach the outside hinge (the one with the crescent shape) directly to the shield. Then (if you're using a bottle), add supports along the inside the shield to keep it open. NOTE: I used aluminum banding and tape for visual purposes. Screws, hot glue, or zipties are all good alternatives.

Step 3: Misting System

Take the cap off your soap dispenser, and cut the nozzle off, so the pump still works. Make sure there's no soap currently in the pump to save yourself a mess. Get your tubing (you shouldn't need more than 6ft) and tape or glue one end to the cap of the soap dispenser so that you can still use the pump. I learned that a clip from a bread bag makes pumping the system much easier. On the other end of your tubing, cut it so that it can run from your hip to the top of your shield without getting in the way. Then take a separate piece of tubing(3-12inches,depending on how many misters you want on on the shield), and add T-junctions with a few inches of tubing and a mister on each end. You can choose to run the tubing through the holes in your banding and protrude through the shield, or just through the attachment on the exterior hinge. Fill the soap bottle with alcohol or disinfectant and pump or siphon the fluid through the system to get it started!