Update 2020-04-03: We were featured on the Etobicoke Lakeshore Press podcast. Click here to listen to the episode on YouTube (also available on Apple Podcasts).
The COVID-19 virus started to affect us directly on the evening of Wednesday, March 11th as I was heading to bed. I realized that I should probably stock up with enough food and supplies for at least a week. By the end of the next day we had started self-isolation as encouraged by the City of Toronto. Over the next few days I started to see notices on social media about how makers could respond to the health care crisis. Then the notices became requests for help. So I signed up New Toronto Makeshore to a couple of lists. There were a few emails in response to an international list, but the list that made the next step more viable was with Community Make, a variant of the Toronto Maker Festival. Once connected with them I had a group to coordinate with and a place to drop off whatever I could make.
It became clear by March 21st that the situation was serious, so I started prototyping some of the designs using an Ultimaker 2+. During the interim I also assembled an Ender 3 that had arrived but was not yet functional.
I started printing these models:
- Prusa RC2 (https://www.prusaprinters.org/prints/25857-prusa-face-shield)
- Shawn Lim
- Shop3D
- MakerWiz https://makerwiz.com/
- Ultimaker https://community.ultimaker.com/topic/31642-coronavirus-lets-do-our-part/
I quickly found that I needed to spend time tuning the slicer settings to ensure the optimal mix of stiffness and speed. If they print too fast the walls aren’t solid and it can easily crack. Go too slow and risk not getting enough out the door. Finally, I figured out the settings in my slicer Cura and set to about a 30% infill, which seemed to work. I found the PETG was too fussy for my printing skill and so I decided on PLA, of which there is more in stock here. I also found the PLA more reliable and sturdy — and it has low odour and low VOC, which is important. in a small makerspace.
We happened to have an old box of overhead transparencies from the office supply store, which are a handy 8.5” x 11” and can be easily adapted to make a barrier that works with the printed frames. The 8.5″ x 11″ size works with the European A4 well enough, which is important if you are printing the Prusa models. Align the centre first, and then work to the edges next. To align the centre, bend the transparency sheet in half (without creasing), mark the middle point, and position the front two pegs. Mark and punch. On the bottom, mark the centre again, and then fit the printed support on. Align the centre hole, ensure a snug fit, and mark the two outer holes. Punch the holes out and re-fit the support. Then, go back and measure and mark the two outer holes on the top headband. Trim the bottom edges a bit so they don’t catch on your clothes. Add an elastic or elastic band, and don yer mask.
While contributing to the Toronto-wide need for PPE, it also occurred to me that I should also check with my local walk-in clinic to see if they could use some face shields. As it turned out they were happy to receive a few and so I dropped off half a dozen. Even though we’re a small makerspace, it’s still important to do what we can to help others. We’ll check in with some of the other businesses in the neighbourhood and donate what we can.
It’s important to note that this makerspace is not set up to manufacture mass production or medical grade parts. Some companies, like Ontario’s Molded Precision Components (full disclosure: my cousin works there) are taking charge and re-tooling to mass produce PPE.
If you think you can help and you live in Ontario, you can check out more resources at: Ontario Together.
Since we are so small there is no way to confirm that the parts are free of the virus. While there is some question as to how long the virus remains viable on non-biological surfaces, we can take steps to make sure the users downstream of the production have enough information to make good decisions:
- Practice consistently washing hands and keeping a physical distance from others when in public
- Monitor body temperature and symptoms of sickness
- Handle printed parts with latex gloves and avoid coughing or breathing on the parts – wear an N95 mask whenever possible
- Be prepared to describe the manufacturing environment, e.g., household or industrial
- Keep printed parts in separate, sealed bags, and
- Label the last time the bags were opened.
I also include a business card in each bag so that anyone opening any one bag will know where the parts originated and how long they have been isolated from human contact. Not perfect, but something.
In the near term, it’s clear that there will continue to be a need for these face shields whether donating through the Community Make initiative, or more locally in the New Toronto and south Etobicoke neighbourhood.
If we can help, we should try.
Prusa RC2 
Shawn Lim design, #thePPEDrive.com
Update: See also this statement from the Government of Canada on 3D printing and other manufacturing of personal protective equipment in response to COVID-19.
