One of the proposed designs uses a flexible silicone mold to cast hard plastic face shield headbands. Each mold can be made in approximately 1 hour and 20 minutes. Each mold can be used to create about 20 bands. Silcast ii (http://www.silpak.com/pdfs/SILCASTIIPDS.pdf) is poured into these molds and sets in about 20 minutes. Each mold has notches that can be drilled out to attach the plastic face shield (not shown) using fasteners. An elastic strap attaches to the back of the band for attachment to the head. The inside of the band is lined with non-porous closed-cell foam for added comfort.
Note! We learned that it is very important that the foam used is non-porous in order to reduce the risk of contamination.