• The Need

    There is a shortage of Face Shields at hospitals for medical responders who are testing and treating COVID-19 patients. Medical responders need to be protected from respiratory droplets from coughing and sneezing. Even though many individuals and groups are designing and manufacturing face shield frames for these responders, many of the designs are not optimized for high-density optimized additive manufacturing and cannot be accessed locally.

    The Solution

    We have designed a face shield frame that is:

    • A downloadable file to enable local production using any Selective Laser Sintering (SLS) Printer
    • Optimized for high-density nesting
    • Made of medical-grade nylon that is autoclavable and compatible with disinfectant cleaners
    • Comfortable due to its flexible, non-rigid, form-fitting design
    • Compatible with bonnets and  bouffants for protection of the forehead and eyes due to the retention tabs
    • Face Shield and a cap for greater protection.

      Two-piece face shield frame printed on a Selective Laser Sintering printer with Medical Grade Nylon 12 (Duraform PA).

    • Render of the 3D Systems face shield design

The Outcome

Face Shield Frame

This face shield frame has been manufactured using medical grade nylons on the following platform:

  • sPro 60, 140, 230
  • ProX 500 and 6100

The design is a two-part flat pack design that will clip into each other to provide structure while minimizing material usage and maximizing the density of parts that can be manufactured.

Face Shields on build plate

98 face shields printed on a sPro 60 in 24 hours

Face Shield

Each face shield can be cut out of a clear sheet material. We recommend 1/32” (0.79 mm) thick clear polycarbonate with holes cut out from a US standard 3-hole punch. Thicker and thinner sheets can also work with this design from 0.008” - 0.04”. The shield protects below the neck and past the temples and gives the user a wide range of motion.

Face Shield cutout pattern

Face shield frame drawing

Splash Guard

Due to the open top design of our face shield frame, there are situations when more protection is required. The face shield frame has retention tabs that will hook standard headwear like surgical bonnets and bouffants to protect your face from aerosol and particulates. Alternative designs for a splash guard are being explored.

Suspension System

Rubber-bands, elastic straps and nylon cord are some of the wide variety of suspension system options available.

Face Shield Splash Guard and Suspension

Face shield frame’s minimal design

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Assembly Directions

Face Shield Clean or Autoclave

Components for Face Shield assembly (plastic + bands x2 + rubber-band) and gloves.

1. Clean parts

by soaking in 70% IPA for ~60 seconds or autoclaving

Face Shield Attaching Polycarbonate sheet

2. Attach the cut polycarbonate sheet

to the with inserts at either end. First by pushing it up under the small retention tab, press your finger down on the plastic and then pull down and across the larger tab. Repeat with the other two tabs.

Face Shield Attach Clips

3. Clip the bands together

Starting from one side, push the end clip of the outer band into the slot of the back frame band. (Note that the 3DS logo on the back band is facing up and that the front band has the 5 small clips on the top of the part.)

Repeat for the other side.

Face Shield Add Band

4. Add a band

Attach at-least two rubber-bands on the back (or however much tension is needed).

Face Shield and a cap for greater protection.

5. Use further protection

For further protection through the opening on the top of the face shield frame, use a bouffant or something similar to put around your head and hook it onto the retention tabs to keep the opening of the frame sealed.

Face Shield Disassembly

6. Disassembly

To disassemble, press the release tab and slide out the front band as shown here.

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Details

Healthcare Infection Control Practices Advisory Committee/CDC Standard Precautions guidelines for prevention of transmission of infectious agents in healthcare venues includes the use of face shields (with a medical/surgical face mask) when sprays, splashes, or splatter are anticipated. 

Disclaimer 

The production of medical parts requires conformance with certain regulations.  The parts and designs shown above do not have regulatory clearance at this time.  Any required validations and regulatory approvals are not the responsibility of 3D Systems.

Any design files referenced or provided by 3D Systems are provided “as-is” without any warranties or guarantees of any kind, including but not limited to, warranties of fitness for particular purposes, merchantability, or non-infringement. Design files for the manufacture of parts for medical use do not include any registrations or certifications. Users of the design files are solely responsible for their use of the design files and any applicable regulatory approvals (or exceptions thereto) and any claims of liability, including but not limited to products liability or intellectual property infringement, and will indemnify 3D Systems for any liability that may result from use of the design files.