Proto Shield

The Proto Shield is an open-source, low-cost, quickly produced face shield. It is designed to be functionally equivalent to the Prusa face shield. It’s just 100x faster to make. The visor is compatible with 3D printed Prusa parts.

Materials for the Proto Shield cost less than $1, and it can be produced by almost any laser cutter in less than 1 minute. It can be stored and shipped flat, is comfortable enough to be worn all day, and can be disassembled for sterilization and re-use. 

One person can make hundreds of Proto Shields in a day from almost anywhere in the world. Here’s how:

Tools

  • Laser cutter (40 watt+; bed size 10″ x 16″ +)
  • Hot knife or scissors
  • Small flat head screwdriver
  • Rubber gloves, face mask, and disinfected work surface

Materials

  • .060” or 1.5mm PETG sheet (approximately 16” x 2” per shield)
  • .020” or .5mm PETG sheet (approximately 9.5” x 9.5” per shield)
  • .75” or 20mm elastic band (approximately 14” per shield)

Cut Files (Single Shield)

Head Band (.060” PETG)

3/4″ Elastic

Cut with hotknife (recommended) or scissors at 14”

Visor (.020″ PETG)

Cut Files (Mass Production w/ 29″ x 19″ or Larger Laser)

Head Band (.060” PETG)

  • Prep Work: Break 4′ x 8′ sheet down into (8) 24″ x 24″ sheets.
  • Yield: 128 Headbands & 128 Bottom Supports per 4′ x 8′ sheet.

3/4″ Elastic

Cut with hotknife (recommended) or scissors at 14”

Visor (.020″ PETG)

  • Prep Work: Break 4′ x 8′ sheet down into (4) 29″ x 19″ and (4) 19″ x 19″ sheets.
  • Yield: 50 Visors per 4′ x 8′ sheet.

Assembly Instructions

Here are all the final components. The elastic band is cut to 14”.
Bend the four tabs out to a 45º using a small screwdriver. The material has plenty of flex and will hold the new shape.
Here are the central tabs, bent outwards.
Don’t forget the horizontal tabs as well.
At this point the components are ready for construction. Your local healthcare center may want them in this state with the plastic coating in place for better decontamination. They could then be assembled on-site.
For assembly, first remove all the plastic coating. Use a small blade if you have trouble getting it started.
Line up the outer slits, keeping the smaller band (with the holes) in front.
Pull the elastic through the first hole from the outside. Give yourself a few inches for the other two holes.
Use this photo as a guide for the path of the elastic.
Then tighten it all up.
Repeat the process on the other side, making sure that the smaller component remains on the inside of the bend.
Here is the final headband, ready for the mask to be attached.
Starting at one side, pop the mask over the tabs. We found it easier to do this if you bend the section you’re working with flat before inserting the tab.
The mask attached to the headband.
The small curved piece snaps into the inside bottom of the mask to hold a curved shape.
The curved piece in place.
Please share this album and the cut files with anyone who could help out.

License

Creative Commons License
Proto Shield by Mat Thorne and Devin Montgomery is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
Based on a work at https://www.prusaprinters.org/prints/25857.

Legal

This design and these instructions are provided for free and as-is. Neither Protohaven nor the creators of the design and instructions offer any warranty or assume any liability for their use.