Face Shield - No Experience or Advanced Tools Needed

This Face Shield is based on the design from Zac from GimmeBuilds, with the modification of an adjustable and more comfortable back strap. This design does not require a 3D printer or Laser Cutter to create, and can be made solely with materials from local stores. This should improve the ease of making Face Shields and allow them to be produced by individuals and organizations who wish to help but do not have access to a 3D Printers and Laser Cutters.

However, there is an optional 3D printed part but it can be replaced with a zip tie.

The cost per face shield is approximately $1.07. Attached is a google doc with links to the materials we used.

Supplies

Plastic Pipe Hanger

Laminating Film

Zip Ties

Elastic Band (1" is ideal)

2 3D printed pieces OR 2 extra zip ties

Step 1: Preparing Your Workspace

It is important to assemble the Face Shield in a clean workspace. To accomplish this, clean your workspace before beginning assembly with a disinfecting cleaner. In addition, wear gloves and a mask if possible while working on the Face Shields to reduce the risk of contamination.

Tools Needed:

• Scissor
• Hole Puncher
• Xacto Knife/Box Cutter
• Sharpie or similar marker
• Optional: 3D Printer

Step 2: WARNING!

Check your instruction card to see if you are working on Version 1 or Version 2 of the face shields. This will be noted at the bottom of the instruction card that came in the kit of supplies. It is extremely important that you follow the instructions on how to place the zipties for the version you are working on.

Step 3: Cut the Plastic Pipe Hanger

Cut 2 strips of Plastic Pipe Hanger. The first should be 16.5" (22 holes) and the second should be 15" (20 holes).

Note: We used Plastic Pipe Hanger with a 3/4" center-to-center distance between the holes

Step 4: Round the Edges of the Longer Band

Round the edges of both bands to eliminate the sharp corners

Step 5: Attach the Two Bands

Version 1

1. Place the bands as shown in the picture, with the shorter band above the longer band
2. Line the first hole on the shorter band up with the fourth hole on the longer band
3. Feed a zip tie through as shown in the picture
4. Tighten the zip tie and remove the excess
5. Repeat steps 2-4 on the other side

Version 2

1. Place the bands as shown in the picture, with the shorter band above the longer band
2. Line the first hole on the shorter band up with the fourth hole on the longer band
3. Feed a zip tie through as shown in the visual guide above for version 2 (not the pictures)
4. Tighten the zip tie and remove the excess
5. Repeat steps 2-4 on the other side

Step 6: Prepare the Elastic Band

1. The best elastic to use is buttonhole elastic. However, that is not widely available. To make your own, take a normal elastic band and cut 1/2" slits every 3/4" inch.
2. Cut the elastic into 5-6" strips, making sure there is a buttonhole slit at each end.

Step 7: Add the Elastic Band

If you have access to a 3D printer:

1. 3D print the Elastic Band Clip and Pin
2. Push the pin through the last hole in the longer band from the inside
3. Add a small bead of hot glue on top of the pin
4. On the outside, place the Clip on top of the pin and push it on all the way. It is a pressure fit and may require a little bit of force when connecting
5. Add the elastic band onto both clips

If you don't have access to a 3D printer:

1. Use a ziptie to connect the Elastic Band to the last hole of the longer Band

Step 8: Cut the Face Shield Material to Size

Version 1

1. Cut the plastic material you are using to make the face shield to the correct size. We are purchasing them precut as 8.5"x11"
2. Round the bottom two corners on the bottom side (an 11" side) to minimize sharp corners

Version 1

1. Cut the plastic material you are using to make the face shield to the correct size. We are cutting them from larger sheets to be 9.5"x14.5"
2. Round the bottom two corners on the bottom side (a 14.5" side) to minimize sharp corners

Step 9: Attach the Face Shield to the Band

Version 1

1. Hold the face shield up to the band, and starting at one end, cut slits using an exacto knife at each point where a ziptie (shown in the version 1 section of the graphic in red) is required
2. Secure the shield at each point using a ziptie
3. Repeat steps 1-2 for each required ziptie

Version 2

1. Hold the face shield up to the band, and starting at one end, cut slits using an exacto knife at each point where a ziptie (shown in the version 2 section of the graphic in red) is required
2. Secure the shield at each point using a ziptie
3. Repeat steps 1-2 for each required ziptie

Step 10: Completion!

You should have a finished face shield!

Comments

[drdunc1000]

Tip 1- You can use stiff wire instead of the zip tie
Tip 2- Attach the visor to the visor band before attaching the visor band to the headband
Tip 3 - Make a template for the holes in the visor by folding a piece of paper around the piece of plastic to form a pouch with one open end. Punch holes in the end of the pouch at the correct spots. Then slip the plastic into the pouch and punch the holes.
Tip 4- Make a template for the 20-hole piece and mark holes 10 and 11 with a marker and tape the piece to the table. Make a template for the 22- hole piece and cut BEVELS on the ends instead of rounding them. Tape this on the table. Cut a piece of stiff wire that is the distance between holes 1 and 4 and tape that onto the table
Tip 5 - Use rubber bands instead of the elastic. Attach one end of the rubber band with the stiff wire (tip 1) or the tie wrap. Push the other end through the hole in the headband. You can then adjust the tightness of the headband by pulling more or less of the rubber band through the hole.

[travis.merritt]

Very detailed tips. I love the idea for Tip5!

[travis.merritt]

I like how you use one zip tie to go through two holes to attach the 20 hole piece to the 22 hole piece. I used a different technique. I applied 1 zip tie to each side first and left the second hole (the one that is critical for stabilizing the front of the face shield) for the plastic visor. Since I used an 8.5 in x 14 in plastic, I needed to use this hole for a zip-tie to hold the first corner of the visor. I ordered from Lamination Depot.

[Penolopy Bulnick]

Nice job on your first Instructable :)