Face Shield Visor for COVID-19 Frontline Workers

Welcome to the assembly instructions for Makers4Medicine's Face Shield! The benefits of this face shield design are:

3D Prints in 25-30 minutes! Laser cuts in 1-2 minutes!
Uses common off-the-shelf components available from Office Supply and Home Improvement stores
Easy to assemble, take apart and disinfect
Comfortable removable closed-cell anti-microbial foam headrest. Also prevents sweat from forehead entering eyes.
Can be shipped completely flat when disassembled.

This guide will help you assemble the face shield. It should only take a few minutes! Let's get started.

Supplies

3D Printed Visor (see Thingiverse for 3D Printing instructions)
Clear Plastic Shield (10mil 8.5"x11" clear binding report cover)
Foam Headrest (5/8" backing rod)
Elastic Band (1/2" wide seems to work best)
Rubber Band (3 1/2")

Step 1: Attach Clear Shield to Visor

Attach the clear plastic shield to the visor by popping it onto the 5 studs in the visor. Once all 5 holes have been secured, tuck the ends of the plastic shield into the small hooks on both sides of the visor.

Step 2: Clip Foam Headrest Onto Inside Edge of Visor

The foam headrest has been sliced down the middle. Find the opening with your finger and open it up along the length of the headrest. Gently clip or slide it onto the inside edge of the visor.

Step 3: Attach Rubber Band to Front of Face Shield

If clear plastic shield doesn't seem secure on the visor, or if it pops off after prolonged use, use a rubber band to keep the plastic shield secure. Start on one end of the visor and wrap the rubber band around the stud, then pull it and continue on to the next stud. Wrap the rubber band around that one too, and continue until the rubber band has been wrapped around all studs.

Step 4: Tie Elastic to Visor

Simply tie the elastic to the holes in the visor. Don't tie a knot until you are sure the length is comfortable for you!

Step 5: Finished!

All done! You can easily disassemble and reassemble the face shield multiple times for disinfection and cleaning.

If you need to replace any of the parts, here is a part list:

The clear plastic shield is a 10mil 8.5"x11" binding report cover, available at office supply stores. Punch holes in the appropriate spots and round of the corners with scissors.
The foam headrest is "backer rod" available at home and garden stores. It is used to fill gaps behind panels. It is waterproof and anti-microbial. It is similar to the toy foam "pool noodles" but much smaller.
Any elastic band that fits in the holes will work!
The visor is the only part that is not easily replaced because it is 3D printed. But if you have a 3D printer, you can find the file here: https://www.thingiverse.com/thing:4236924

Thanks again and stay safe!

Step 6: Round Corners With Scissors (if Needed)

We normally pre-punch the holes and round the corners before we send the kit, but some of of our early kits came with square corners. If your clear shield has square corners, simply round them off with scissors as shown in the picture. Don't worry about getting it perfect! The main reason for these rounded corners is so that the bottom corner of the shield doesn't collide with your shoulder when you turn your head from side to side.