COVID-19: Rapid prototyping and production of face shields flat, laser-cut, and 3D-printed models.
Sean O'Connor, Snehamol Mathew, Foram Dave, David Tormey, Una Parsons, Mel Gavin, Paul Mc Nama, Ruth Moran, Mark Rooney, Ross McMorrow, John Bartlett, Suresh C Pillai
Author Information
Sean O'Connor: Department of Environmental Science, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Snehamol Mathew: Centre for Precision Engineering, Materials and Manufacturing (PEM) Centre, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Foram Dave: Centre for Precision Engineering, Materials and Manufacturing (PEM) Centre, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
David Tormey: Centre for Precision Engineering, Materials and Manufacturing (PEM) Centre, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Una Parsons: Faculty of Engineering & Design, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Mel Gavin: Contract Research Unit, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Paul Mc Nama: Contract Research Unit, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Ruth Moran: Contract Research Unit, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Mark Rooney: Yeats Academy of Arts Design & Architecture (YADA), Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Ross McMorrow: Faculty of Engineering & Design, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
John Bartlett: Department of Environmental Science, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
Suresh C Pillai: Centre for Precision Engineering, Materials and Manufacturing (PEM) Centre, Atlantic Technological University, ATU Sligo, Ash Lane, Sligo, F91 YW50, Sligo, Ireland.
The use of personal protective equipment (PPE) has become essential to reduce the transmission of coronavirus disease 2019 (COVID-19) as it prevents the direct contact of body fluid aerosols expelled from carriers. However, many countries have reported critical supply shortages due to the spike in demand during the outbreak in 2020. One potential solution to ease pressure on conventional supply chains is the local fabrication of PPE, particularly face shields, due to their simplistic design. The purpose of this paper is to provide a research protocol and cost implications for the rapid development and manufacturing of face shields by individuals or companies with minimal equipment and materials. This article describes a best practice case study in which the establishment of a local manufacturing hub resulted in the swift production of 12,000 face shields over a seven-week period to meet PPE shortages in the North-West region of Ireland. Protocols and processes for the design, materials sourcing, prototyping, manufacturing, and distribution of face shields are described. Three types of face shields were designed and manufactured, including Flat, Laser-cut, and 3D-printed models. Of the models tested, the Flat model proved the most cost-effective (€0.51/unit), while the Laser-cut model was the most productive (245 units/day). The insights obtained from this study demonstrate the capacity for local voluntary workforces to be quickly mobilised in response to a healthcare emergency, such as the COVID-19 pandemic.
