Lasercut PPE Face Shields

Our goal is to get as many suitable PPE units as possible into the hands of healthcare workers asap.

To meet this goal, I designed an acrylic version of the Prusa RC2 face shield that could be lasercut at ~3-5 min per unit (vs the 2-5hrs it would take to 3D print a single RC1 or RC2 unit). In the time it takes to 3D print one visor, I estimate we can lasercut ~48 ones instead.

Based on the Prusa Protective Face Shield RC2, these shields are compatible with Prusa’s lasercut “visor/front plate” transparent plastic sheet template & elastic solution.



Above: Testing the first visor prototype

FACE SHIELD PARTS

Lasercut 3mm Acrylic visor

Elastic Strap (320mm)

EVA Foam* (optional)

Clear Plastic Shield*

*EVA floor mats and 8.5×11 Transparency Sheets were used in photo examples)

Download Files

Highlights:

Uses same clear plastic shields as Prusa’s Face Shield design

Clearance space to fit over average face masks & glasses

Acrylic is a non-porous material (visor component can possibly be sterilized & reused?)

Forehead padding, elastic strap, and clear shield can be removed for disposal/replacement

EVA foam, cloth, etc can be used as optional forehead padding

Cutting Files:

faceShield_visor

faceShield_shield

faceShield_EVAfoam (optional)

Helpful Templates:

Elastic Band Template (For cutting holes into elastic ribbon)

Shield template (For punching holes into plastic sheets by hand)

Notes:

For .AI files, Red is cut, black is engrave.

For clear shields, make sure whatever material you’re cutting is safe for your lasercutter. (i.e., don’t lasercut clear vinyl if you have a CO2 laser, etc)

Cut visor out of 3mm Acrylic material. Fold ribbon and cut small slits at marked intervals to create holes.

Photos:

FAQ:

How do we contact you for more information?

E-mail us at hello@burbankmakerspace.com

Why did you design this?

If the hospital workers fall, then we all fall. We want to help with the massive PPE shortage by making the most of our resources. We have a lasercutter, and we can lasercut these visors much faster than we can 3D print them.

How many visors can you cut per hour?

Our software is estimating we can lasercut 24x visors in an hour on one lasercutter.

Are you aware that there’s an even faster PPE design using plastic and weatherstripping?

Yup, and it’s awesome! Again, any and all PPE is great right now to help out emergency workers. Use whatever you’ve got to make stuff to help– whether it’s 3D printers, lasercutters office supplies, etc.

Why aren’t you making the faster design?

My main concerns are speed PLUS supply & demand of BOM components needed for any PPE solutions. Personally, I’m worried that a lot of these unique BOM components are going to run out w/o a clear restock date. I’m already seeing thick weatherstripping out of stock in local stores and on Amazon. Our design is just another alternative solution using materials that are currently still available in large supply.

Has your design been reviewed by a doctor?

Technically, yes… and no? Full disclosure– I’m from a large family of physicians & medical professionals, including my parents. My mom is a retired infectious disease specialist, and my dad is a urological surgeon. I’ve had lots of discussions with them about face shields & medical staff needs, and I sent them photos of my lasercut design for review. Both gave valuable feedback, and encouraged me to move forward and share this design.

Of course, if there’s any LOCAL medical professionals who would like to test and review this design in person, please contact me.

Why are you not 3D printing the Prusa design?

Honestly, because it’s a bottleneck for us. While we have 7 active FDM 3D printers in house, only two of them have heated beds required for printing the recommended material, PETG. Of those two, only one of them has a large enough print bed to fit the preferred RC2 model.

We estimate on average, each 3D printed RC1 Prusa Face Shield would take about ~2hrs or longer to print each unit (estimated for FDM printers, .3 layer height, PETG material). In the time it takes to 3D print one visor, we estimate we can make 48 lasercut ones.

Why do you prefer the RC2 model over the RC1 one?

Don’t get me wrong– they’re both great designs and ANY PPE is better than nothing right now. However, IMHO the smaller RC1 design is uncomfortable to wear for the long 8-12hr shifts at hospitals.

How is this compatible with Prusa’s Face Shields?

Same dimensions & mounting peg locations as Prusa’s RC1 and RC2 designs’.

Why did you make this compatible with Prusa’s Face shields?

To utilize the most out of the resources available by trying to adhere to one “standard” Face Shield. This way regardless if workers have a lasercut visor or a 3D printed one, they can use the same shield and have those made/donated to them in bulk.

How long does it take to lasercut one visor?

Lasercutting time will vary based on individual machine settings and wattage. For us, our software estimates a single visor will take about 3min to cut.