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Step-by-Step Instructions for DIY COVID-19 Face Shield

Below are detailed instructions ant tips on how to make your simple DIY COVID-19 Face Shield, similar to the one we made in the YouTube video below.

A) Materials Required

You will need these four things to build your DIY COVID-19 Face Shield:

  1. A piece of transparent plastic (find it on amazon.com)
  2. A piece of elastic (find it on amazon.com)
  3. A piece of foam (find it on amazon.com)
  4. Something to tie the Elastic to the Plastic

A.1) A Piece of Transparent Plastic (find it on amazon.com)

The easiest to use are the binding covers or the presentation covers, which can be obtained in office supplies stores. We are using Staples Presentation Covers. Box of 100 sells for CAD 77.00.

The presentation covers are just about the right size for a Face Shield. They are a little larger than the standard Letter size paper (8.5x11"). A4 size also works well.

The presentation covers we used is 0.0065" (0.16 mm) thick. If you can find thicker covers, they should be more durable. Just make sure that they are transparent enough.

Some of the presentation covers that are sold are semi-opaque, even though it says on the box that they are transparent.

If you cannot find the presentation covers, or you don't want to spend money buying them, the good news is that nowadays everything is wrapped in plastic and you may be able to find pieces of transparent plastic that are big enough to act as a face shield.

Below are just two examples:

  • Spinach tub lid

  • Hallmark greeting cards box lid

 

You will only have to cut the edges, trim it to right size and peal off the labels, which can sometimes be tricky. The trick is to do it slowly.

A.2) A Piece of Elastic (find it on amazon.com)

You will need approximately 13" (33 cm) long piece of 3/4" or 1" (20 to 25 mm) wide general purpose elastic, like the ones shown in the photo, to make a comfortable head band.

We bough ours at Walmart. You can also buy them at arts and crafts stores and sewing supplies stores.

If you cannot find the elastic in stores, or to save money, you may be able reuse a piece of elastic from an old pair of underwear.

Even a couple of rubber bands could work, although a nice wide piece of elastic makes wearing the Face Shield much more comfortable.

 

 

A.3) Piece of Foam (find it on amazon.com)

The quickest way to build a DIY COVID-19 Face Shield is using a self adhesive foam window seal (weather stripping). For best results use minimum 3/4" (19 mm) wide by 1/2" (13 mm) thick foam.

This should be available at all hardware stores. We bought ours at the Home Depot.

You can also use thinner weather stripping, but in that case you should use two layers.

In case you don't have the weather stripping, you can use any other type of foam, like a strip of packaging foam (shown in the picture below) or a piece of Styrofoam, which you can easily cut to the right size using a sharp Exacto knife.

If the piece of foam you are using doesn't have the adhesive back, you will have to use some kind of glue to glue it to the plastic piece. We found that the regular hot-melt glue gun works the best. Use the low temperature setting, as the high temperature may damage the foam.

A.4) Something to tie the Elastic to the Plastic

You can attach the elastic to the plastic in a couple of ways. Our first idea was to use heavy duty self-adhesive Velcro (which we bought at the Canadian Tire). We found that it sticks very well to both the clear plastic sheet and to the elastic. The width of the Velcro should match the width of the elastic, i.e., 3/4" or 1" (20 to 25 mm) wide. (find it on amazon.com)

Velcro can have a dual purpose, to attach the elastic to the plastic sheet and to make the length of the head band adjustable.

We also tried various sticky tapes (like Duct Tape), however, they didn't stick to well to the elastic and they tend to tear after a while, so stay away from those.

After a lot of trial and error, we found that the best results in connecting the elastic to the plastic sheet were achieved using an office stapler.

Any old stapler, like the ones shown in the picture, will be adequate.

 

 

 

 

 

 

B) Step-by-Step Instructions

  1. Cut all parts to size
  2. Attach one side of the elastic to the plastic sheet
  3. Glue the foam to the plastic sheet
  4. Attach the other side of the elastic to the plastic sheet
  5. You are done!

B.1) Cut all parts to size

Cut all material to the following sizes:

Transparent plastic: approximately 11 inches wide x 8.5 inches high (28 x 21 cm). A little smaller should still be OK. If you are using a report cover, you don't need to do any cutting as it is already the correct size.

Elastic: 13 inches long.

Foam: 10 inches (25 cm) long, or about 1 inch (2.5 cm) shorter than the width of the plastic sheet.

B.2) Attach one side of the elastic to the plastic sheet

Attach the elastic to the top corner of the transparent plastic sheet. The elastic will wend up on the front side of the plastic sheet. The easiest and sturdiest method is to staple the elastic to the plastic sheet.

B.3) Glue the foam to the plastic sheet

If you are using the self adhesive foam, simply line up the foam with the top of the plastic sheet, stretch it a bit and press it down onto the sheet. Make sure that the foam doesn't stick above the sheet.

It is best to attach the foam a few millimeters below the top of the sheet. This is important so that the adhesive on the back of the foam does not stick above the plastic sheet.

If you are using regular packaging foam or Styrofoam, you should glue it using a glue gun. Because these foams aren't as flexible as the weather stripping, you should bend the foam piece before gluing it to the plastic.

 

Detailed instructions on how to build your own DIY COVID-19 Face Shield will include photos, measures, specifications and tips & tricks.

B.4) Attach the other side of the elastic to the plastic sheet

The final step is to staple the other side of the elastic to the opposite top corner of the plastic sheet. It is best to do this from the outside. If needed you may temporarily peel back the end of the foam, so that you don't staple through the foam.

B.5) You are done!

Your DIY COVID-19 Face Shield is completed and it is ready to be used!

Stay safe and share this information with others. Don't share the Coronavirus!

Copyright Trimill