Shield Makers

Meeting the demand of PPE for healthcare workers during COVID-19.

Face Shields are in short supply due to COVID-19. Shield Makers is a dedicated team of individuals designing and creating face shields for those who need them most. 

 

Our mission is to fill the dire need for face shields for medical workers at Rancho Los Amigos National Rehabilitation Hospital, and Los Angeles County Department of Health Services facilities. 

PARTNERSHIP WITH:

CONTEXT

Non-profit Effort

ROLE

Project Lead

Industrial Designing, Concept Development, 3d Printing, 3d Modelling, 3d Rendering, Rapid Prototyping

TEAM

Hon Li

Tricia Sada

Skyler Coppenrath​

Morgan West

DesignMatters @ ArtCenter

SPECIAL THANKS TO

Andy Lin

Chris Hacker

Real Shields for Real People

To date, Shield Makers has fabricated and delivered over 4,600 face shields, and counting to hospitals in the LA county area.

10. Rancho nurses Joan Paguio, Austene B

Key Criteria

While reviewing dozens of our own prototypes and prototype submissions, we formulated 3 key criteria that our design uncompromisingly needed to meet. 

Safety

Full Face Protection

180 degrees of protection

from aerosols.

Aseptic Surfaces

Shields need to be wiped down, or able to withstand the sterilizing equipment such as autoclaves and steam tables.

Quality

Comfort

Face shields can be worn for 8-16 hours at a time depending on the shift being worked, therefore pressure on the head and weight were two large considerations.

Durability

Withstand quick movements,

impacts, and dropping.

Sustainability

Refurbishable

The design must have Interchangable pieces, should any piece break. The process can be completed without the need for extra tools.

Evaluating Prototypes

 

We received prototypes and ran them through rigorous quality testing. Some designs cracked and fell apart, others fogged up too much. We shared our findings with resident doctors and therapists at Rancho for professional validation.  

Fabrication Processes

We weighed the pros and cons of the manufacturing processes we had access to. Various individuals, institutions, schools and corporations were able to help.  Below are the processes we evaluated through prototyping. 

We ultimately chose to focus our main production on 3D printing and molding/casting.

Hand 

Cutting

 

Affordable tooling (x-Acto/home tools)

 

Large scale empowerment

 

Fluctuations in quality 

 

Difference in materials

 

Possible contamination

Laser 

Cutting

 

Rapid production

 

Cost effective per unit

 

Machine availability

 

Confined to materials that safely "offgas" when cut

3d 

Printing

 

Low to high tooling cost

 

Easy to outsource

 

 

High cost per unit

 

Questionable sterilization of materials

 

PLA? ABS? Ridges? Porous?

CNC

Routing

 

Low machine time cost

 

Flat cut potential

 

Machine availability

Molding and

Casting

 

Low tooling costs/flexible tooling

 

Materials can be sterilized

 

Need outdoor ventilation or a fume extractor

PPE required due to toxic/hazardous materials 

Injection

Molding

 

Quality and consistency

 

Materials can be sterilized

 

High tooling costs

 

Long lead time due to tooling

Die 

Cutting

 

Low tooling costs

 

Encourages flat cut designs

 

High demand

 

Material waste

IMG_4046.JPG

3D Printing

Monoprice was kind to donate 25 of their MP10 3D printers. We built and put the printers to work immediately. We 3D printed mold cases as positive.

Molding and Casting

We 3D printed mold cases as a positive, then used a platinum low viscosity silicone to create molds. We then poured a 65 Shore D Polyurethane (Silcast ii from Silpak) to create the headbands

Creating the Mold

Pouring Silicone Molds

The mold boxes were 3d printed. Mold release was sprayed inside the molds and a LV Silicone was mixed and poured into the mold case. 

Removing Mold Post Cure

After roughly 1 hour the mold is ready to be released from the mold box. 

Mold Cleaning

The molds needed a bit of trimming and fine tuning to be ready for the pouring of polyurethane.

Casting the Headband

Mixing and Pouring Casts

Part A and Part B are mixed up 1:1, with each cast using approximately 30 grams of polyurethane material. 1 gram of blue pigment was added for color, and mixed thoroughly for 30 seconds.

Pulling + Curing Casts

The molds needed a bit of trimming and fine tuning to be ready for the pouring of polyurethane.

Trimming and Sanding Cast

The flashing on the cast needs to be trimmed and sanded. 

Final Prep and Shield Assembly

Tapping face shields for riveting

On the shield, through holes for rivets are tapped into place. We also created a jig and drilled larger stacks for quicker production. 

Drilling rivet holes 

Indents to indicate drilling were created in mold. These hole were drilled out with a 1/8" drill bit. 

Riveting and assembling

Once all parts are prepared and finished, the shield is riveted to the headband, and the elastic strap and foam padded are applied. 

Bill of Materials

Headband

Cast or Printed

$0.70 per unit

Closed Cell Foam Padding

$0.70 per 8.5 inch piece

5/8” Buttonhole Nylon Elastic 

$0.70 per 12 inch piece

 

1 Mil PET Front Shield (9x11”)

$0.50 per unit

1 Mil PET Top Shied

(Not pictured)

$0.50 per unit

Thank You to Our

Healthcare Workers!

The best part was the people we were making the shields for. The wearers of our shields were not only happy with the quality of the product but also knowing that we were thinking of them and actively doing something to help. 

shieldmakers.org

Our website allows the team to coordinate with volunteers, and share our learnings with others. 

@shieldmakers

Our Instagram account allows us to be in direct contact with the healthcare personnel that need shields, and gain insights and feedback on what to improve. 

Shield Makers in Featured Publications:

Call To Action

We are a group of students & professionals from ArtCenter College of Design who are working closely with Rancho Los Amigos National Rehabilitation Center, ArtCenter faculty, and Supplyframe to design face shields.