Face Shield With Replaceable Screens for Loupes

Hi there! We are Atomic Carrots and have been making these face shields over a year, since the beginning of the pandemic and have tinkered a lot with the materials and design. These face shields were designed with the help of dental hygienists to accommodate loupes.

The great thing about this design is that the screens are replaceable and you can flip the screen up (although it won't always stay up). The visor is light and sturdy - it can take a beating.

There are two versions of this face shield - Extended and Extra Long Extended. The Extended version extends 2 3/4" from the forehead and the Extra Long Extended extends 3 1/4” from the forehead. They both use the same screen but the visors are different.

This particular method of fabricating will require a CNC or Laser cutter and knowledge in bending plastic.

Supplies

2 12mm x 3mm Machine Screw from Bolt Depot

8mm RD X 6mm X M3 - Thumb Nut from Amazon

2- #6 SEA Washer (optional)

4 - Double Cap Rivets (63 Z) from Pet Hardware

1/4” x 7” - Expanded Foam from Amazon

10” x 5/8” - Webbed Elastic

Heat gun

1 sheet of PETG .03” - for the screens

10” x 8” sheet of 1/16 ABS plastic - for the visor

1 sheet of 1/32 HDPE plastic - for the head band

CO2 Laser cutter (Optional)

CNC Machine

Step 1: Step 1 - Screen

Download the file “Screen.svg” and cut the PETG on either a laser or CNC machine. For the CNC machine we used a 1/8 straight bit.

Step 2: Step 2 - Visor

Download the file “Visor - Extra Extended.svg” or “Visor - Extended.svg” depending on the length desired. Drill the holes with a 3/32 straight but and the profile with a 1/8 straight bit. You can get away with cutting everything with a 1/8 bit but we like drill in the machine screws so they don’t come loose over time. Use 1/16 ABS plastic, 3/32 ABS will work as well but we’ve found it adds unwanted weight.

Drill in the machine screws in the singular hole on each end.

Take a look at the “Guides.svg” to see where to bend the visor. Place the visor on a hard edge with the machine head facing inward, then heat the edge with a heat gun to bend the leg down. For this delicate process we created a jig to align the visor.

Step 3: Step 3 - Head Strap

Download the file “Strap.svg” and cut the 1/32 HDPE plastic on the CNC machine. We’ve cut the strap on our laser but have to do 2 passes because HDPE tends to melt.

Use a 3/32 bit especially for the lines in which the elastic will go through - this will add tension and prevent the elastic from sliding overtime.

Remove the paper backing from the foam to stick it to the center of the strap. This should provide adequate cushion when wearing the shield.

With the double caped rivets join the legs of the visor to the strap.

Step 4: Step 4 - Assembly

You are almost there!

Below is a video on the best way to attach the elastic. Finally, above is a video on how to install and replace your screen.

Step 5: Step 5 - How to Clean

The visor can take tougher chemicals. The screen should be cleaned with diluted alcohol using a non-textured wipe. Cavicide wipes can scratch the plastic over time because of the textured wipe. If Cavicide is used, we suggest it as a spray and remove residue with a damp wipe.

We know this is a tedious project - our hopes is for our design to live somewhere besides our desktop in the hopes that one day it will benefit someone. Feel free to visit our website - atomiccarrots.com or contact us at [e-mail]

Thank you