Laser Cut Designs

This design uses a laser cutting machine to cut out the headband and shield.

This is the most time-efficient method since laser cutting is a very fast process. However, laser cutting can only use materials that are safe to laser cut such as acrylic or thin plastics. There are two different laser cut designs, depending on what materials you have available. 

  Flat Acrylic Design  

This design is best if you have a large supply of Acrylic

Materials Needed (for 1 face shield)

  • 1/8 to 1/4 inch thick Acrylic

  • 1/8 inch wide (or wider) EVA Foam (or other nonporous foam)

  • 3/4 inch wide Buttonhole Elastic or other material to attach shield to head

  • 9 inch by 11 inch transparent material for shield (ex. PVC)

Step 1

Laser cut acrylic piece

Step 2

Laser cut or hand cut transparent shield

Step 3

Attach foam to inner edge of acrylic piece

Step 4

Insert transparent shield into slot of acrylic piece

Step 5

Pull top of transparent shield about half an inch above the acrylic piece. An optional step is to add a piece of tape to this top edge of the transparent shield to secure the shield to the headband.

Step 6

Attach buttonhole elastic to sides of acrylic piece. If you are using a different material than buttonhole elastic, secure the material as needed.

Step 7

Place shield on head using elastic strap. In the case that the acrylic piece breaks, use extreme caution as acrylic is very sharp when fractured.

  Band Design  

This design is best if you have a heat forming tool for acrylic, or thin polycarbonate material and rivets

Materials Needed

  • 0.03 inch thick flexible material such as PETG​​ (Note that it is important not to use a thicker material as it  becomes unsafe to laser cut for thicker plastics)​

  • Acrylic can be used in place of plastic if you have a tool to heat form the acrylic (It is not ideal to use acrylic in this manner as it is sharp and dangerous if it fractures)

  • 1/8 inch wide (or wider) EVA Foam (or other nonporous foam)

  • 3/4 inch wide Buttonhole Elastic or other material to attach shield to head

  • 8 rivets

  • 9 inch by 11 inch transparent material for shield (ex. PVC)

Step 1 

Laser cut the two flat bands

Step 2

Laser cut or hand cut transparent shield

Step 3

Attach transparent shield to outer band using the two innermost holes and two rivets.

Step 4

Rivet outer band to inner band using next 2 holes on each side of the band.

Step 5

Rivet elastic to headband using remaining two holes.

Step 6

Line the inner band with foam

SHIELD MAKERS

  • instawhite