Page tree
Skip to end of metadata
Go to start of metadata

Contact: Doug Daniels 

dougdaniels@library.ucla.edu



Table of Contents




We are working as hard as we can to get things moving, thank you for your patience. I will be creating a listserv and include everyone that has reached out to me and expressed interest in helping. So please keep contacting Doug Daniels, even if this page seems out of date we are doing what we can. 

If you absolutely cannot wait to get started printing, you're awesome. We will very soon be able to help get supplies to other area hospitals. If you want to 3D print something in the meantime that will have a very high likelihood of making its way to a hospital, we would recommend the following:

  • This STL: Face_shield_FixedOrientation.stl

  • Printed in PLA

  • 0.3mm layer height, supports enabled, 10% infill, 3 shells. Other settings use what works best with your printer.

Goals

  • Develop and disseminate methods to manufacture PPE for medical personnel using 3D printing and other rapid prototyping techniques.

  • Consolidate information related to these efforts, including design ideas, results of medical evaluation of prototypes, and key persons involved throughout the LA area and beyond.

  • Provide instructions and guidance on how individuals and other institutions can contribute their time and energy to these efforts.

IMPORTANT: Unless otherwise explicitly stated, nothing on this page is officially sanctioned by UCLA or UCLA Health. You should be in touch with your local medical facilities if possible in order to find out what kind of equipment they need, and what kind of equipment they can accept.



Overview


This document summarizes current activities related to the manufacture of PPE equipment for medical facilities in response to the COVID-19 pandemic. It is meant to help you navigate some of the more promising designs that we've encountered. You absolutely must consult with medical professionals in your area before settling on a design.


Current status of this effort at UCLA is as follows: 


  • Several design iterations have been assessed by UCLA Health, each of which is very similar to the ones pictured on the right.
  • Designs from Prusa and DTM have been among those handed over for assessment.
  • Design changes have been made by UCLA's 3D print club. Changes have included closing off any open area between the shield and the HCW's forehead.
  • Valve splitter designs are nearing their final iterations.
  • Disposable face shields have started production.
  • Injection mold design for face shields is in the works.





Primary Considerations

These considerations are mission critical and are applicable to any 3D printed PPE. 



Material Choice

Evaluating materials with respect to sterilization methods is critical. Choice in materials can also greatly affect production capability and availability of supply.

Recommendation: for large scale production, evaluate common materials first, such as PLA or ABS, to ensure compatibility with the largest number of 3D printers in your area. If part of a coordinated effort, make sure you're all using the same material as that which your medical personnel have approved.


ProductionSupply
Not all 3D printers can print with the same materials. The more common the material, the greater the number of available 3D printers that can be used for production. This is why ABS and PLA are strongly recommended to be the first material to be considered, regardless of which medical device is being evaluated.Materials like PLA and ABS are in ready supply. More specialized materials, such as PETG, may be more difficult to procure in the quantities necessary to produce 25,000 face shields.

Manufacturing Environment

Stringent requirements on the environment in which parts are produced will limit production capacity greatly. 

Recommendation: prioritize development of post-production sterilization methods instead of during production. Develop industry and community partnerships to sufficiently increase production capacity.           

                                                                                                                                                                                                   

Local production

Industry production

Although possible to more strictly control the manufacturing environment at your own campus or institution, this may restrict availability of resources. Instead, priority should be given to evaluating the possibility of sterilizing equipment after the fact.

With the exception of medical device manufacturing companies that already use 3D printing techniques, it is not realistic to plan on sterilizing or otherwise maintaining sanitation standards on facilities that are not controlled by your institution. Furthermore, production of parts in the quantities that are required will necessitate making use of industry's production capacity.







Face Shield Designs


  • Consult with the appropriate medical personnel in your area about which design to produce. The designs we have listed here are not formally approved by any medical professional or organization, but will give you a good head start.

  • Keeping in mind that you might need to make thousands, if not tens of thousands of these devices, you'll want to make sure you choose a material that has the lowest chance of running out. PLA or ABS are great. Something like PETG, although better than PLA and ABS in many ways, may be in short supply.

  • None of these designs are meant to be masks, nor are they meant to replace N95 masks. If we come across designs meant to replace N95s that we think deserve consideration by professionals, we will share them here.



DTM Visor Shield Design

InstructionsDesign FilesProduction Notes
Google DocDTM Shield V3.stl

Based on the feedback from physicians at UCLA Health, the prototype that was evaluated had a large gap at the top of the user's head, allowing aerosols to fall through and into the user's face. This design was created after similar feedback from Boston and Seattle hospitals.

  • 0.2mm layer height
  • 30% infill
  • 3 shells
  • Supports disabled


Prusa Face Shield 

InstructionsDesign FilesProduction notes


Prusa Mask Instructions.pdf

Headband V1.stl - smaller, designed to maximize production.

Headband V2.stl - larger, designed for comfort rather than mass production

Headband V3.stl - closes the gap between headband and forehead. Note: requires supports to be enabled.

Bottom reinforcement.stl

Prusa face shield template.ai

Both v1 and v2 of the headband design are viable, and both designs work with the face shield template. The designs differ in size, and so both should be made to ensure a more comfortable fit for the end user. Prusa's recommended settings are viable, however a design using the following settings was selected as the preferred design:

  • 0.3mm layer height
  • 0% infill
  • 10 shells
  • Supports disabled (EXCEPT for V3, which needs supports enabled)

3/24: prototypes have been assessed by UCLA Health and were rejected due to a large gap at the top of the mask that would allow aerosols and other particulates to land on the HCW's face.


Budmen Industries Face Shield

InstructionsDesign FilesProduction notes
Budmen Mask Instructions.pdf

Face shield.stl

Strap lock.stl

This design is less efficient than Prusa's but is still viable. Because a viable prototype was made using Prusa's design, we have not continued with our evaluation of this design beyond its printability. If you have notes on this design, please contact Doug Daniels dougdaniels@library.ucla.edu


3D Verkstan Face Shield

InstructionsDesign FilesProduction Notes
LinkVisor frame v3.stl

This design is markedly smaller than the Prusa, and therefore can be theoretically manufactured faster, in larger quantities, and for less material. The design is intended to work with a standard 3-hole punch and a letter sized face shield (8.5" x 11"). This shield may prove to be too small, and the design may need to be tweaked.

Note: the prototype currently being evaluated was printed in PLA. Therefore, any determination made will be applicable to a PLA print of this design.



Splitter Valves for Ventilators

Examples of parts required are shown. I am gathering more information, but currently my understanding is that efforts are being made to secure a facility that can produce the necessary STL files.

Update (3/24): Open source project on these designs: https://github.com/helpfulengineering/project-4-way-ventilator/tree/master/02_Development

Printing two sets of valves, one using PLA another set using a Form 3 resin printer for evaluation by UCLA Health.

   



The Prints

Here I've documented our work printing samples of the various masks linked above. 

The selected prototype was the Prusa design using these print settings:

  • 0.3mm layer height
  • 0% infill
  • 10 shells
  • no support

The material used was PLA.



 MakerBot Z18 - Two copies of each of Prusa's design
Build Pate

Print Details

SettingsPrint time

  • 0.2mm layer height
  • 0% infill
  • 10 shells
  • No supports

Approximately 19h 50m

    

 Replicator+ (MB85) - 2 copies of Budmen masks
Build PlatePrint DetailsSettingsPrint Time

  • Printed on Replicator+
  • Two copies of Budmen's mask design
  • These settings are actually the settings that were recommended by Prusa. Because this design doesn't need to be flexible, we can likely lower settings to quicken print time.
  • MakerBot print file
  • 0.2mm layer height
  • 30% infill
  • 3 shells
  • No support

Approximately 5 hours

    

 Replicator+ (MB84) - One copy of each Prusa, recommended settings
Build PlatePrint DetailsPrint settingsPrint Time

  • Printed on the Replicator+
  • One copy of each of the Prusa masks, using the settings that are recommended by Prusa.
  • MakerBot print file
  • 0.2mm layer height
  • 30% infill
  • 3 shells
  • No support

Approximately 7h35m


 Replicator+ (MB86) - Both Prusas, Z18 settings
Build PlatePrint DetailsPrint SettingsPrint Time

  • Printed on Replicator+
  • One of each of Prusa's design
  • Settings are different from the recommended settings, same as the Z18 print. I have a hunch these will be the ideal settings, so I wanted to print the same set on a different printer to compare.
  • MakerBot print file
  • 0.3mm layer height
  • 0% infill
  • 10 shells
  • no support

Approximately 7 hours


 Replicator+ (MB87) - Two Budmen, recommended settings.
Build PlatePrint DetailsPrint SettingsPrint Time

  • Printing on Replicator+
  • Using settings recommended by Budmen, which are very minimal, as reflected by the print time.
  • MakerBot print file
  • 0.3mm infill
  • 10% infill
  • 2 shells
  • no support

Approximately 3h50m






Available Resources at UCLA

These are the labs at UCLA that have committed resources or are potential resources to be tapped. Daily print capacity is a rough estimate. Laser cutters are for the plastic face masks that need to cut to size and so they can be attached to the 3D printed parts.

Lab NameLab Location3DP Capacity (face shields)Laser cutters
UCLA Library Lux Lab - Doug DanielsYRL and Powell~12-15 per day, 24-30 counting overnight prints1x 18x24"
Engineering Lab - Jacob SchmidtBoelter~160 / day2x 18x32"
ORL MakerSpace - Charly MelikidseRieber Hall4-5 per day
Guido Faas - UCLA NeurologyNRB~12 per day
Pretty In Green - Chris ErnstOff campus, not UCLA50-80 per day



Other Schools & MakerSpaces

Lab/School NameLocationCapacity
Wildwood SchoolLos AngelesRoughly five 3D printers.



Potential Industry Partners

These are industry groups that have contacted us and expressed their desire to help with this effort in any way that they can. To achieve production numbers that will be required, it is all but certain that we will need to tap into this resource.

Business PartnerPoint of contactOverview of SupportPotential Capacity
PrinterPrezzAlan Dang - alan.dang@printerprezz.comPrinterPrezz is a medical device manufacturer that uses 3D printers and has capabilities to manufacture in an ISO-13485 environment.Unknown
JabilGeoffrey Doyle - geoffrey_doyle@jabil.comJabil is a manufacturing company with a presence in the Bay Area, and is in conversations with UCSF on production of medical devices.Unknown
Northrop GrummanChris De Young - chris.deyoung@gmail.comA contact at Northrop Grumman has contacted the manager of their fabrication lab who is excited to support the effort. They are in talks with their own legal team about feasibility of helping this effort.About 10 3D printers available of various types some prusa's, some Zortrax, some Utilimakers.
SMS EnergeticsScott Genta - sgenta@smsenergetics.comSafety Management Services has business partners that might be able to join this effort. Our point of contact may be able to connect us with companies such as Honeywell.N/A
Pretty In GreenChris Ernst - chriswernst@gmail.comSmall business operated by husband and wife team that produces 3D printed pots, gardening supplies, and plants.15 3D printers, all FDM
Bega North AmericaTed Knaziawycz - tedk@bega-us.comDesigner and manufacturer of lighting and illumination technology.Unknown
ArkturaChris Kabatsi - covidresponse@arktura.comManufacturer of custom architectural systems.30-50 3D prints, potentially thousands of plastic sheets.
MatterHackersMara Hitner - mara.hitner@matterhackers.comLargest supplier of 3D printers and filament. Priority contact for crowdsourcing efforts, including 3D printing manufacturers, the public, and various businesses.Potentially thousands.
HoneywellMark Knowles - Mark.Knowles@Honeywell.comDesign Director at Honeywell, Aerospace division, willing and able to muster department's 3D printers (and others) to help make headbands.~ 120/day
HPDavid Pierick - david.pierick@hp.comManager of application engineers for 3D printing at HP in San Diego. Industrial capacity, nylon powder prints.Thousands per day - on the expensive side but they are reusable.
3D Printing NerdDavid Tobin - david@the3dprintingnerd.comHost of the YouTube channel 3D Printing Nerd. 380,000 subscribers, many connections to the maker community.



Key People

In order to better facilitate coordination and cooperation between all parties, I will keep a running list of persons that have been looped into this effort as well as their role, both from UCLA and elsewhere.

If you want to modify, add, or remove your information, please email me: dougdaniels@library.ucla.edu 

UCLA

Name and DepartmentContactRole
Doug Daniels, UCLA Librarydougdaniels@library.ucla.eduHelped produce first prototype of face mask that is currently being evaluated. Facilitating communication between relevant parties. Curating project information, progress, and results.
Jacob Schmidt, UCLA Engineeringschmidt@seas.ucla.eduProfessor of Bioengineering, director of Engineering makerspace - largest potential production capacity on campus.
Dana Schmitz, David Geffen School of Medicinedkschmitz@mednet.ucla.eduDirector of alumni affairs. Coordinating and facilitating communication between parties involved.

Partner Institutions 

Name and InstitutionContactRole
Barbara Bernoff Cavanaugh, University of Pennsylvaniabbc@pobox.upenn.eduAssistant University Librarian for Health Sciences & STEM Libraries; point of contact for efforts underway at UPenn.
Karen Estlund, Colorado State Universitykaren.estlund@colostate.eduDean of Colorado State University Libraries
Geneva Henry, The George Washington Universitygenevahenry@gwu.eduDean of Libraries and Academic Innovation. In communication with researchers at GWU that are currently evaluating industrial hygiene and effectiveness issues.
Varvara Kountouzi, University of Pennsylvaniavarvarak@upenn.edu3D printing manager. Has delivered two prototypes to hospital for evaluation.
Brad Spellberg, USCspellber@usc.eduChief Medical Officer at the Los Angeles County-University of Southern California (LAC+USC) Medical Center
Laura Taalman, James Madison Universitylaurataalman@gmail.comProfessor of Pure Mathematics. Access to personal fleet of 3D printers as well as on-campus 3D printing classroom. Total of up to 22 3D printers.
Devayan Bir, Loras CollegeDevayan.Bir@loras.eduProfessor of Engineering; 4 3D printers ready to be put to work.
Kristen Schreck, Saint Xavier Universityschreck@sxu.eduChair, Mathematics. Ultimaker 2+ able to print with PLA.
Kurt Helgeson, St Cloud State Universitykrhelgeson@stcloudstate.eduChair, Environmental & Technological Studies; 12 3D printers and 6 laser cutters.
Kevin Mardirossiankevin.mardirossian@gmail.comFive 3D printers, capable of printing Ultem filament (autoclave safe)
  • No labels