The 2-minute G-shield.

Construction:

We came up with a design that can be made in about 2 minutes per unit, when built in series with one person building it. That’s easily 80X faster than 3D printed anything. And can be built by anyone who does not have a 3D printer.

Besides improving yield, this design tackles the issue of safety and prevention of the unintended consequences of good-will contamination. We designed these to provide system, specs, and assembly instructions to hospital personnel so they can setup an assembly line in a controlled clean environment based on their emergency standards. As compared to having everyone build these anywhere, without standards and then send (possibly contaminated) units to hospitals.

How to build these:

Step 1: Cut your grid of shields from 4x4 sheet (yields 25 shields) or 4x8 sheet (yields 50 shields) of PETG 0.020” thick (thinner is too flimsy, thicker is too hard to cut and too much resistance against elastic.

Step 2: Miter corners

---- Steps 1-3 can be skipped if shields clear sheets are ordered pre-cut, info below ----

Step 3: Cut 0.75 inch thick polyethylene foam spacer from sheet/roll

Step 4: Apply spray adhesive (or strong double sided tape)

---- Steps 3-4 can be skipped if foam spacers are ordered pre-cut + with adhesive backing pre-applied info below ----

Step 5: attach foam strip to PETG shield

Step 6 (added after testing): remove chunk of foam for upward exhaled air venting (prevents fogging)

Step 7: Staple 0.75” thick (14” long) braided elastic band (or substitute, hair bands work too) ---- if elastic folded over before stapling it will be stronger —

All explained here:

Sourcing: (relevant for northeast USA region)

Dr. Sergio Waxman is implementing this design for Beth Israel Medical Center in NJ. Here is his sourcing information (there may be more convenient ones for your area).

1. Clear PETG Plastic Face Shield

.020” x 9.50” x 9.50” (2 cut corners 1/4” radius)

(Pre-cut saves time on assembly)

Supplier 1:

Emco Industrial Plastics, Inc.

99 Commerce Rd

Cedar Grove, NJ 07009

#800-292-9906 x1113

Direct #973-559-8062

www.emcoplastics.com

Supplier 2:

ACME Plastics, Inc.

222 Browertown Rd

Woodland Park, NJ 07424 US

2. 2.2# PE (polyethylene) strip

1” x 8” x .75” with PSA (adhesive) one side (1” x 8")

Most manufacturers are willing to add the adhesive (saves time on assembly)

Supplier 1:

New England Foam

760 Windsor St.

Hartford, CT 06120

860-524-0121 - Phone

860-522-5830 - Fax

New England Foam Products Home Contact Us Avada's Humbled History Fit-Foam-Function Foam Types Available New England Foam supplies, converts & fabricates the following types of foam: Open-cell Polyurethane

Supplier 2:

New Industrial Foam Corporation

1355 W Front St, Plainfield, NJ 07063

newindustrialfoam.com

(908) 561-4010

3. Elastic band:

Dritz 3/4″ Braided Elastic

Item Number: 9534B

Dritz 3/4" Braided Elastic - Dritz Insert into casings or stitch directly to wrong side of fabric. Care: Machine washable and dryable in temperatures up to 200°F. Chlorine bleach and salt water safe.

(Got it from JoAnne Fabrics, also available in Walmart/E-bay/other retailers)

4. Staples and elastic band:

Heavy Duty One Touch Stapler (STAPLES Store)

Heavy-Duty Staples



We are continuing to work on more solutions trying to address similar PPE needs and safety requirements. You can follow progress in my LinkedIn (https://www.linkedin.com/in/gustavo-fontana-5a24a21/detail/recent-activity/)

Any questions/concerns please email/text/call me.

Best wishes to everyone and stay safe out there,

Gustavo

Gustavo Fontana

Fresco Design

Co-Founder / Creative Director

+1.617.233.5844

gustavo@fresco-design.com