UW MEDICAL FACE SHIELD ASSEMBLY JIG

This is an assembly jig for the UW Madison COVID-19 Face Shield. See this website for details on the shield design: https://making.engr.wisc.edu/shield/

See it in action here: https://www.youtube.com/watch?v=Gp61NSQn5dA

This jig assists assemblers with placing the foam strip for the headband while also allowing space for stapling. Some assemblers have used 2-sided tape to mount the jig to a table. Others simply mount it to a small piece of plywood.

I am providing two versions. V1 is a 2D cut file that can be cut with a laser or CNC machine. V2 is an STL for 3D printing.

V1 (DXF) Notes:

-Use heat set inserts in all holes of base. I used this product: https://www.mcmaster.com/93365a120

-All other holes are through holes for size 4-40 screws.

-Two clip versions are offered- one with a slot for adjustable width and one with a fixed hole. Use whatever works best for you.

-Material thickness isn’t critical, but 3/16 of an inch or thicker for the base is recommended to accommodate the height of the inserts. Thinner base material would work with standard nuts- they will just protrude from the bottom of the base.

-Material thickness for the middle isn’t critical either, but should be at least .06in thick.

-Choose fasteners length based on you material selection.

V2 (STL) Notes:

-Uses 4-40 fasteners and 4-40 hex nuts.

-Two clip versions are offered- one with a slot for adjustable width and one with a fixed hole. Use whatever works best for you.

-Prints well on a Prusa printer. May not work well for a smaller printer bed.

-Small holes in the middle of the base are for 1/16 pins. Lengths of large paper clips cut with a wire cutter act as suitable replacements.

-Small holes in the clips are also for 1/16 pins or large paper clip lengths to prevent rotation. Many people find pins for clips are not necessary.