Rapid Production Face shield – 35min print – add on visor – US/A4

UPDATED 04/11/2020: After playing around with the stock Prusa frame, it turns out that if you flip the frame over and install the shield with the pegs on top, you can use the 10mm height v2 visor and it fits great. Check photos for reference. Work with US(3) and A4(4) hole layouts.

I was able to make a v2 work for 15mm height frames so that has been added. Work with US(3) and A4(4) hole layouts.

UPDATED: We revised the visor design to work on low profile frames (10mm) that have either 3 or 4 holes and improve fit. DXF and .stl files uploaded. Working on refining two more options for 15mm and full height 20mm sized frames. New version is visor-10mm v2.

The frame has also been changed slightly to work better with standard 8.5″x11″ shield stock by extending side tabs and includes a slight flare to the arms to increase comfort. A 3 peg version has been added for US. New version is faceshield_optimized_v8.

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Thank you everyone for the hard work, contributions to the community effort, and for keeping designs open for remix!

This remix is a combination of a few ideas. It takes an optimized frame in terms of protection, comfort, and print time and pairs it with a shield that provides more side coverage and a visor that is laser cuttable.

This is designed to save time and filament. In my workflow, 3D printing is the bottleneck and a laser cuttable visor means I can produce 2-3x the face shields per day.

The design has gone through a number of iterations over the past week based on feedback from medical professionals in Orlando, FL. Thank you to Swami from Factur MakerSpace for his help and expertise and thank you to Factur for letting me use their laser cutter and doing all they can to help.

Frame:

Time to print is 35min per frame with a .6mm nozzle, .48mm layer height and some aggressive tuning in PrusaSlicer. Luckily no overhands or bridging required so can really push the profile. The frame minimizes filament while adding additional coverage on the sides by holding the wider shield closer to the sides of the face with tabs. Peg length extended to accommodate more visor thickness options. Brow kept wide to ensure a comfortable fit.

3 options provided with and without material choice clearly printed on the side along with appropriate recycling logo.

Shield:

The shield is optimized for 12″x12″ stock that we had available and is cut to be 11.5″ wide. The hole placement is the same as prusa’s 4pin layout for maximum compatibility. The bottom tappers to make it easier to turn your head without hitting shoulders.

Visor:

The visor can be added to already printed frames. It was created by taking the NIH approved visor and flattened with patterning software and modeled tabs so that it can be added to the Prusa 4-hole layout. The removable visor can be 3D printed or laser cut for maximum efficiency.

I have tried 3D printing the visor at .8-1mm thickness PETG, laser cutting out of .020″ stock, and hand cutting out of 10 mil PVC. All have worked, the major limitation is the peg length on Prusa frames and should be taken into consideration when choosing materials as they have to stack.

Two versions have been provided to accommodate different frame heights. Frame height measurement is front frame that holds the shield. Stock Prusa is 20mm and the frame in this remix has reduced height down to 10mm.

.step files have been provided for all components. Please be aware that the visor hole locations may need slight adjusting based on your frame design and shield/visor material thickness.

Bottom Reinforcement:

An extra perimeter has been added to the outside to avoid printing artifacts and issues with .6mm nozzle print.

Assemble Instructions:

Material thickness will effect how you stack the shield and visor components. The outside holes will either go over or under the shield holes depending on materials used. Middle holes always go under. Good luck!

Note: DXF = 1mm

UPDATE: 04/07/2020 – I’ve been working on optimizing slicer setup and since there are no overhangs or bridging I was able to get print time down to 35min with a .6mm on a MK3s. PrusaSlicer files added. Aggressive print settings and speed intended for PETG