White Label Face Shields

Overview

Due to COVID-19, hospitals are experiencing a face shield shortage. To help solve this, an engineering team created an open-source face shield for mass manufacturing. Use the files below to start your own production line.

This design is based on the Prusa Face Shield, and aims to improve the design in two important ways:

Sterilization – The original design includes a 3D printed headband that is difficult to sterilize. This headband has been replaced with an injection-molded polypropylene part that is compatible with nearly every hospital sterilization method including the autoclave.
High Volume Production – Using injection molding and die cutting, you can produce tens of thousands of face shields every day.

Downloads

Headband - Injection Mold Design

This headband was designed to be mass manufactured using plastic injection molding. Download the STEP file and share it with a plastic injection mold company. Let them know you would like the part to be made out of Polypropylene, and tell them how many parts per day (ex: 10,000) you need them to produce so that they can calculate how many molds and mold cavities will be required.

An STL file is also included in the download, so that you can 3D print a sample to show to a hospital.

Shield - Die Cut Design

This shield was designed to be mass manufactured using die cutting. Download the DXF and PDF files and share them with a plastic die cutting company. Let them know you would like the parts to be made out of PET plastic in any thickness from 0.18 to 0.5 millimeters (0.007 to 0.020 inches), and tell them how many parts per day (ex: 10,000) you need them to produce so that they can calculate how many dies will be required.

Another option for material is a specialty plastic called PPSU (Polyphenylene Sulfone). This will cost more than PET, but the benefit is that PPSU may be cleaned in an autoclave without damaging the material, meaning the entire face shield may be put in an autoclave without disassembling it.

Strap - Die Cut Design

This strap was designed to be mass manufactured using die cutting. Download the DXF and PDF files and share them with a rubber die cutting company. Let them know you would like the part to be made out of Natural Rubber, Synthetic Rubber, or Silicone Rubber in a thickness around 0.8 to 1.6 millimeters (1/32 to 1/16 inch) and a Shore A hardness of 40 – 55. They will have several options, and will provide you with samples you can select from. Tell them how many parts per day (ex: 10,000) you need them to produce so that they can calculate how many dies will be required.

Assembly Instructions

Share this brief video with health care clients, assembly technicians, and anyone else who will be assembling these face shields.

Sterilization Compatability

Headband (Polypropylene Plastic)

Strap (Rubber)

Shield (PET Plastic)

About Us

Director of Innovation & Technology
Sears think[box]
Case Western Reserve University

Engineering Project Manager
Nottingham Spirk

Head of Medical Plastics Center of Excellence, School of Engineering
Penn State Behrend

Credits

People: Mark Bartlett, Amy Bridger, Ainsley Buckner, Ari Jay Comet, Sean Connole, Brandon Cornuke, Malcolm Cooke, Jeff Horneman, Trevor Jackson, Laura Johns, Thomas Kadavy, Marlo Dreissigacker Kohn, Ray Krajci, Kip Lee, Jim McGuffin-Cawley, Tiffany McNamara, Mike Pintz, Darcy Rees, Chris Roberts, Steve Rosenzweig, Brian Rothstein, Tim Simpson, Nori Swennes, David Sylvan, Perry Wood, Gary Wnek, Chris Zorman

Organizations: Case Western Reserve University, Nottingham Spirk, Penn State Behrend, Sears think[box], Erie County Gaming Revenue Authority, Bliley Inc, Port Erie Plastics, Die Cut Products, Munot Plastics, Musson Rubber, Novus Applications, University Hospitals, Cleveland Clinic Foundation, MAGNET