Face Shield for Healthcare Providers (No 3D Printer Needed)

At a time when surgical masks are desperately needed for healthcare providers, you can create protective face shields at home with these simple instructions. Face shields are an effective way to protect against the spread of droplet-born viruses like Coronavirus (and the resulting disease Covid-19). They can be cleaned and re-used and are more comfortable to wear than a mask. When worn with a face mask, a face shield can prevent droplets from even reaching a face mask. Face shields should fit snugly on the forehead area to prevent slippage. For improved protection from infectious agents, face shields should be, at a minimum, full face length with outer edges of the face shield reaching at least to the point of the ear, and cover from the forehead to the chin. A cushion over the forehead can help to ensure that there is adequate space between the wearer’s face and the inner surface of the visor, particularly for those who wear glasses.

Supplies

The materials in this project are easily obtained from a hardware store and do not require a 3D printer.

Flexible clear plastic sheeting (search for acetate, propionate, and polycarbonate). The thickness should be between 10 Mils and 20 Mils. I used this Clear Banister Safety Shield, which is 15 Mils thick and works well.
Foam tape or weatherstripping – get the thickest kind you can find. I used this Frost King Air Conditioner Weatherseal, which is 1.25" x 1.25". (Some weatherstripping has adhesive on one side already, but I was unable to find any in a thickness that was satisfactory.)
Mounting tape (double-sided).
Velcro fastener (wide, reusable, non-stick application).

Tools required:

Stapler
Scissors
Utility knife
Framing square
Lots of clamps
Scrap plywood for cutting surface

Step 1: Measure and Cut the Plastic Sheeting

Cut a face shield measuring 12" wide x 9.5" from top to bottom. Use a straight edge and a utility knife. I recommend using a carpenter's square and several clamps to prevent slippage.

Step 2: Add Mounting Tape

Add mounting tape to the top inside of the shield.

Step 3: Round the Corners

Using scissors, round the corners at the bottom of the face shield.

Step 4: Mount the Foam Padding

Cut a 12" segment of foam padding with scissors, remove the tape backing, and stick the foam pad to the mounting tape.

Step 5: Cut Two 10" Segments of Velcro

Cut two 10" segments of velcro.

Step 6: Staple the Velcro to the Face Shield

Using a standard office stapler, attach the velcro straps to the top outside of the shield. Staple with the pointed sides out, binding together the foam padding, face shield, and velcro. Two staples on each side should do it. Make sure the same side (either hooks or loops) faces out on both the left and right sides.