During this epidemic, the need and demand for PPE has increased. Masks are now a requirement in most public places both in the US and worldwide. Masks have been shown to slow the spread of the virus, but there are some obvious disadvantages. Masks cover the majority of one’s face. This removes nonverbal face cues as a form of communication especially in schools and in the workplace. This is especially hard for the non verbal communicators. In addition, people touch their face while donning masks which tend to decrease their efficacy. Glasses fog up and most masks do not fit most faces. However, face shields allow the user to protect their face from particulates while still ensuring that your face is seen. This can possibly be a different alternative than a cloth mask or homemade masks especially when in close contact with others. But face shields are bulky and hard to carry around. “Face It” combines portability and flexibility so the average person is able to carry a face shield with them throughout the day. The headband is engineered for both flexibility, sturdiness, and adjustability. Our “roll up” technology turns a bulky system into a lightweight cylinder that is the size of your average water bottle.

What it does?

"Face It" does what all face shields so, which is protect the user from microbials and particulates especially when in close contact with others. What makes are face shield different is it that is:

  1. Flexible design enables it to be rolled up into a cylinder the size of a water bottle
  2. Adjustable headband for all head shapes and sizes
  3. Can be sterilized and clean for continuous use

How I built it

The 3D models were designed in SolidWorks. The prototype model was built using a Monoprice Select Mini 2 3D printer using TPU for the Headband and PLA for the packaging. We used Powerpoint to create a presentation and narrate over the slides as well as Google Drive to share information, pictures, videos, and SolidWork files.

Challenges I ran into

The main challenges was designing the cushioning portion of "Face It". The 3D model would not render the piece sufficiently on the surface of the adjustable headband due to a slate and curved surface. This is where the bulk of the time was used. Another challenge is the 3D printer needing to be calibrated for a specific type of material and successfully printing (no cracking or gaps) the prototype.

Accomplishments that I'm proud of

We are proud of the prototype we were able to print especially under the time constraints. Unfortunately, we did not have the full two days to do this challenge due to personal circumstances, but we are excited to know that we finished and were able to successfully 3D print a prototype.

What I learned

We learned that designing a product has its ups and downs. There are certain issues you cannot plan for and the time crunch did exasperate some problems. We learned the SolidWorks can be picky and not enable you to build on slanted and angled surfaces. This is in reference to the cushion portion of the product. We learned that material changes in 3D printers can be problematic if it is not calibrated correctly. We learned that there comes time when you have to stick with an idea and not continuously change it as you build it or you will never finish building it. We learned there is power and working to everyone's strength in the team so that each person can work simultaneously in order to bring the product pieces together.

What's next for "Face It" by Intellect Designs

We believe this is a simple, but useful product. As schools and businesses open up, this can be a another layer of protection for the everyday citizen. The headband can be manufactured in different colors or even have designs especially for children. The carrying case can be turned into a pocketbook/handbag or a strap can be added to the packaging. The headband design itself lends to the flexibility of the face shield so that can be patented and possibly licensed.

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