This is our version of the COVID-19 face shield made by Prusa, with improvements developed by other sources.

Materials

Some of our materials
  1. 3D printed parts
  2. Transparency film (like this)
  3. Elastic band or rubber bands (like this)
  4. Hole puncher
  5. Tape
  6. Zip ties
  7. Foam strip (like this)

3D Printing

For our version of the face shield, we use the Maker Nexus remix of the Prusa face shield. Get the latest release of the face shields here and download the zip file.

Unzipping the file, you will see a lot of files and folders, but we will only use the files contained in the "fab" folder.

Now, open up your slicer, and import the necessary STL files. If you are printing with PETG, import the thin shield with support. If printing with other materials, import the other shield with support. In both cases, also import the bottom reinforcement.

If you are printing using a Prusa printer, there are also pre-made gcode files included for printing. Otherwise, you can use the print settings recommended by Maker Nexus.

Transparent Film Parts

There are two parts of the face shield that are made from transparent film: the "visor" and the "crown." The crown is needed for hospital use, while a visor-only face shield can be used personally or in a clinic setting. In order to make these parts, first print out the needed templates. While printing, use letter size paper and print at 100% scale.

Settings for printing using Chrome

Put the transparent film on top of the template, trace it with marker, and cut it out. Use the hole puncher to punch the holes marked on the templates as well. The visor template is truncated so that it can be printed, so the actual visor is longer than the drawing shows. The most important holes are the four connecting the transparent film to the headband, so make sure to punch those holes accurately.

Assembly

Maker Nexus has a video showing how to assemble their face shield, but ours is slightly different. You can use the video to help you through the assembly process.

  1. Add foam tape onto the 3D printed headband. This is in order for the headband to be more comfortable for long term use.
  2. Attach the crown to the headband. Then, use a zip tie to tie all of the crown pieces together. Try to keep the middle piece on top of the others, so that the seams face backwards instead of forwards for more protection.
  3. Attach the visor to the headband.
  4. Tape the edges between the crown and the visor.
  5. Add the elastic band in the back. If you are using rubber bands, tie 2 or 3 of them together to form the band.
  6. Add the bottom reinforcement to the visor, and tape it on so it is more secure.

Then, you have your own face shield!

Face shields are in high demand at your local hospitals, clinics, and senior care centers, and for many other COVID-19 responders. If you have access to a 3D printer, join us in making them and donating them to protect our heroes.

Overview of our efforts to combat COVID-19 by Andrew, one of our members
Alternative face shield idea by Aprille, one of our members

Additional Resources

Prusa Assembly Guide

MakerNexus Assembly Guide

SF Bay Area COVID-19 Face Shield Projects

Contact

If you need additional help, contact me at andrew@techdreams.foundation and I will answer your questions as soon as possible.