Ethan Rhodes
The COVID-19 pandemic caused a global shortage of personal protective equipment (PPE) in hospitals, including face shields. Many companies and community groups have since mobilised to manufacture and donate face shields to hospitals in need. This paragraph will explore the methods and materials used to make face shields for hospitals.
| Characteristics | Values |
|---|---|
| Purpose | To protect healthcare workers eyes and face from the virus spread by coughs and sneezes of infected patients |
| Material | Plastic, foam, elastic, PET, PLA, TPU-93A filament, ABS-42 filament, PET-G |
| Design | Flip-up face visors with adjustable head straps, padded for extra comfort, lightweight, clear plastic, raisable protective shield |
| Manufacturing technique | 3D printing, laser cutting |
| Ease of use | Easy to wear while performing jobs, without irritation or strain |
| Reusable | Yes |
| Disinfection | Easy to disinfect and decontaminate |
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What You'll Learn
Sourcing materials
Plastic
Plastic is the primary material needed for making face shields. It is used to create the protective shield that covers the face. There are different types of plastic that can be used, such as PET, PET-G, or biodegradable materials like PLA. Some community groups and companies have used 3D printers to create plastic face shields, demonstrating the accessibility of this method. Reach out to local 3D printing enthusiasts or community groups to source plastic face shields or collaborate on production.
Elastic
Elastic bands or straps are necessary to secure the face shield comfortably on the wearer's head. Elastic bands can be sourced from various suppliers, including craft stores or online retailers. When sourcing elastic, consider the length, width, and stretchiness required for a comfortable and adjustable fit.
Foam Padding
While not all face shield designs include foam padding, it can be a valuable addition for extra comfort, especially during long-term use. Foam padding can be sourced from packaging supply stores or online retailers. Ensure the foam is soft and flexible enough to provide a comfortable cushioning effect.
Clear Plastic Film
A clear plastic film or sheet is attached to the front of the face shield to provide an unobstructed view. This material should be transparent, durable, and easy to clean. It can be sourced from plastic supply stores or online. Ensure the thickness is appropriate for the required level of protection.
Other Materials
Other materials that may be needed include plastic visors, headbands, and fasteners such as hooks or clips. These can often be sourced from local craft stores or online retailers. It is important to consider the specific design of the face shield to determine all the required materials and their quantities.
By carefully sourcing these materials, individuals, community groups, and companies can contribute to the effort of providing protective face shields to hospitals, helping to safeguard healthcare workers and patients during challenging times.
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3D printing
Many organizations and individuals have been using 3D printing to make face shields for hospitals, particularly during the COVID-19 pandemic. 3D printing has been used to create protective equipment for healthcare workers, including face shields and ventilator parts.
One example is the NoCo Face Shield Project, which uses 3D printers to create "Prusa 3D Printer COVID-19 Protective Face Shields" for hospitals facing shortages of protective gear. The group joined a statewide collective called Make4Covid, which helps distribute any excess 3D-printed face shields to where they are needed.
GriffonCo, a 3D printing company specializing in tabletop gaming, also started printing face shields for local hospitals treating COVID-19 patients. They are printing the 6-peg North America version of the 3DVerkstan face shield, and are delivering them in batches of 20-30 directly to hospitals.
Baker Hughes, an energy technology company, is another example of a company using 3D printing to make face shields. They have a large facility in Claremore, Oklahoma, and have partnered with hospitals in the Tulsa area to provide them with face shields. They estimate that they produce about 100 face shields per day and are focused on increasing their production to meet the demand.
In addition to these larger companies and organizations, individuals with access to 3D printers have also been contributing to the effort. For example, Romulo, a member of the NoCo Face Shield Project, used two 3D printers to produce the bottom part of the face shields, partnering with someone who could print the top headband pieces. Similarly, Marian Hamilton, a professor at UNC, and her partner are using a 3D printer to make N95 small personal masks using open-sourced designs, which they distribute to healthcare workers upon request.
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Assembly
Firstly, gather all the components of the face shield. This includes the protective shield, head strap(s), and any padding, such as foam, for added comfort. If you are using a 3D-printed design, ensure that all parts have been printed and removed from the printer bed.
Next, attach the protective shield to the head straps securely. This typically involves threading the elastic or adjustable straps through slots or holes in the shield. Ensure that the straps are tight and secure, as they will need to withstand extensive use and cleaning.
Then, if your design includes padding, attach it to the headband. This is usually placed at the forehead area to provide comfort and relieve pressure on the wearer's head. Ensure that the padding is securely attached and will not shift during use.
Finally, adjust the headband to fit the wearer's head. This may involve tightening or loosening the straps to achieve a comfortable and secure fit. It is important to ensure that the face shield is snug but not too tight, providing a good seal around the forehead and allowing clear vision through the protective shield.
Some face shield designs may have additional features, such as a flip-up mechanism or a raisable protective shield, which can be engaged by the wearer as needed. Ensure that you review the specific instructions provided with your face shield design and follow any recommended assembly procedures.
Once assembled, the face shield should be ready for use, providing protection to the wearer's face and eyes.
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Decontamination
Understanding the Need for Decontamination
Hospitals maintain strict decontamination protocols to prevent the spread of infections and ensure the safety of patients and healthcare workers. Face shields, being in direct contact with patients and medical procedures, can become contaminated with harmful pathogens, including viruses and bacteria. Therefore, proper decontamination is necessary to eliminate these pathogens and prevent cross-contamination.
The specific decontamination methods for face shields may vary depending on the hospital's guidelines and the materials used in the face shields. Here are some common approaches:
- Disinfection with Cleaning Solutions: This method involves using appropriate disinfectants or sanitizing solutions to clean the surface of the face shields. Hospitals typically have approved disinfectants that are effective against specific types of pathogens, such as COVID-19. It is essential to follow the manufacturer's instructions for dilution ratios, contact times, and proper application methods.
- Physical Removal of Contaminants: In some cases, physical cleaning methods may be employed. This can include wiping down the face shield with sterile wipes or microfiber cloths to remove visible contaminants. However, this method alone may not be sufficient for complete decontamination.
- Sterilization Techniques: Advanced sterilization techniques, such as autoclaving, may be utilized for face shields that can withstand high temperatures and pressures. These techniques use steam, heat, or chemical agents to kill all microorganisms, including spores, ensuring complete sterilization.
- Disposable Face Shields: Some face shields are designed for single-use only. In this case, decontamination may not be necessary, as the shields are discarded after each use, reducing the risk of cross-contamination.
Considerations for 3D-Printed Face Shields
With the emergence of 3D-printed face shields, it is essential to consider the unique aspects of decontamination for these shields. The materials used in 3D printing, such as PLA or PETG, may have specific requirements for disinfection. For example, the Scout initiative in Mexico, which donated 10,000 3D-printed face shields, emphasized the importance of proper cleaning between uses. Similarly, Omni3D, a Polish manufacturer of 3D printers, designed face shields that allow for full decontamination, making them reusable for hospitals.
Collaboration with Hospitals
When producing face shields for hospitals, it is crucial to collaborate closely with the medical facilities to understand their specific decontamination protocols and requirements. Hospitals often have dedicated teams or committees that oversee infection control and equipment sterilization. By working together, manufacturers can ensure their face shields meet the necessary standards and can be effectively decontaminated using the hospital's existing processes.
In summary, decontamination is a vital aspect of face shield usage in hospitals, and it requires adherence to strict protocols to ensure the safety of patients and healthcare personnel. By understanding the decontamination methods, materials used, and collaborating with hospitals, manufacturers can play a crucial role in providing effective and reusable protective equipment to those on the front lines of patient care.
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Distribution
For instance, at the height of the COVID-19 pandemic, many educational institutions with access to 3D printers and other resources, such as Western Carolina University and Cornell University, answered the call to produce face shields for healthcare workers. In these cases, distribution was facilitated through partnerships with hospitals and medical centres in their local communities. For example, Western Carolina University's Rapid Center shipped its face shields to Stratasys for collection and further distribution to hospitals and emergency responders.
Similarly, the CommonHealth Project, driven by volunteers in Bergen and Morris counties, delivered 4,000 face shields to hospitals through a well-organised logistics system. This involved a network of constructors, drivers, and coordinators who ensured the smooth running of drop-offs, pickups, and deliveries.
In other cases, companies and organisations producing face shields may have more extensive distribution networks, partnering with multiple manufacturing companies and universities to mass-produce face shields for a wider reach. For example, Nottingham Spirk partnered with researchers, innovation teams, and local manufacturing companies to produce approximately 5,000 face shields each day, with a total expected output of nearly 240,000 shields.
Overall, the distribution of face shields for hospitals requires careful coordination and collaboration between various entities, including universities, manufacturers, hospitals, and community volunteers, to ensure that the protective gear efficiently reaches those on the front lines.
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Frequently asked questions
You will need a 3D printer and a laser cutter. You will also need plastic pellets to melt down to make the shield and elastic to secure it in place.
First, you will need to download a 3D model to print the base for the face shield. Once the base is printed, attach a piece of clear plastic to the front to form the complete face shield.
Face shields are a critical piece of personal protective equipment (PPE) for healthcare workers. They protect the eyes and face from the virus spread by coughs and sneezes of infected patients. Face shields are also reusable, which is cost-effective and environmentally friendly.
