Additive manufacturing technologies enabling rapid and interventional production of protective face shields and masks during the COVID-19 pandemic.

Wierzbicki, Jędrzej; Nowacki, Maciej; Chrzanowska, Marta; Matkowski, Rafał; Ziętek, Marcin; Nowacka, Katarzyna; Maciejczyk, Adam; Pawlak-Adamska, Edyta

BACKGROUND Severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) is transmitted through respiratory droplets and contact routes, hence the demand for personal protective equipment (PPE) has increased during the outbreak of coronavirus disease 2019 (COVID-19). Among the most noticeable shortages was the lack of face shields. The urgent demand for PPE induced interdisciplinary cooperation to overcome the shortages, and additive manufacturing proved to be ideal for the crisis situation. OBJECTIVES To investigate the possibilities of implementing additive manufacturing technologies in the interventional fabrication of protective face shields for medical staff. MATERIAL AND METHODS An Ender 3 Pro 3D printer was used to print headbands and Cura 4.4 was chosen as the slicing software. Open source face shield designs were downloaded as standard tessellation language (STL) files and compared. Only models with scientific support were taken under consideration. RESULTS The mean time for producing the headbands tested ranged from 59 min to almost 3 h, depending on the design. After setting up our low budget printer and choosing the Prusa RC 3 protective face shield as the main product, we were able to fabricate about 30 face shields per week at a cost of about €1 each. During 4 weeks, 126 face shields were produced and delivered to various hospital wards, which substantially eased the shortages. CONCLUSIONS Additive manufacturing enables immediate responses to needs in emergency situations, and allows for mass production of personal protective equipment in a short time due the rapid exchange of data among printer users. Despite the unregulated legal situation and insufficient scientific evidence, such protective equipment has been approved by clinicians and is currently used by medical personnel around the world.