Covid-19 NHS CE-Certified Face Shield

In April 2020, the National 3D Printing Society (N3DPS) mobilised a nationwide network of volunteers to address the critical PPE shortage facing NHS frontline workers during the COVID-19 pandemic. N3DPS developed an NHS-accepted protective face shield design optimised for Fused Filament Fabrication (FFF) desktop 3D printers. The design featured a 3D-printed headband holding clear visor sheets, providing full face and neck protection. Crucially, the headband was engineered to stack vertically, allowing multiple units to be printed on top of one another in a single print job—significantly reducing print time and maximising production capacity. Key specifications included: PLA or PETG filament only, under 1-hour print time per headband, and A4 ISO888 4-hole punch visor configuration. One kilogram of filament produced approximately 50 shields at £1.50 each. The design worked towards CE certification under PPE Regulation 2016/425 and EN 166 (Personal Eye Protection), collaborating with the Office for Product Safety and Standards on compliance guidance. Working with partners including RS Components (400kg filament donation), igus UK (central assembly hub), and MedSupplyDrive UK (NHS distribution), the initiative coordinated over 1,750 FFF printers achieving 30,000+ weekly production capacity. Collectively with other UK groups, over 250,000 visors were produced in two months. When government guidance changed, remaining visors were donated internationally via the Red Cross.