Hi everyone its Jake here from 1st Track Dents, I'm still in lock down and unable to work,
so I've put all my efforts into helping out with the shortage of personal protective
equipment (PPE) for all the important medical staff and carers on the front line in
the battle of coronavirus and just to stress I'm not making any money from
this video so that's why I haven't monetized it. So I've used all my design
skills to come up with this it's a medical visor design that's so simple
and so super quick to make and best of all it doesn't require a 3D printer
because not everyone has a 3D printer and I believe currently it takes between
one and three hours to make one medical visor
whereas this design takes between 40 and 50 seconds to make each one and some
poorer countries may not have the 3D printing capabilities to print these
visors in large volumes so It'd be great to share this video to show people that
there is a much quicker alternative out there, so I'm going to show you how easy
these are to make, so in the description i've left a link for a free PDF download
for all the measurements cutouts and templates on how to make your own forming press
Obviously as a disclaimer if you take on this project you do so at your
own risk my design can be made with basic tools and equipment there's
nothing complicated about this design and anyone can make them I think be
great for schools colleges and universities who are already making 3D
printing ones to make these alongside them and for that matter any businesses
around the world that have workshops. it's made from a single piece of plastic
with a groove in the front which allows it to be worn on your head
just using a single piece of elastic strap and because of the shape that can
be tightly packaged together on top of one another which takes up very little
room which means lots of them can be shipped out in one go the flat section
of the headband here makes it really comfortable to wear and the space at the
front here means you can wear a protective medical face mask and because there's
no sponge on the headband section here to absorb sweat that can be wiped down
and cleaned easily and shared by different people, right so let me show
you how you can make these in four easy steps...
So step one you need to download the PDF document because inside here you'll find
all the templates and the measurements to allow you to make these visors you
can do this by clicking the link down below in the description which should
take you to a page on my website on each template I've put some measurements so
you can check whether your printers printing these off accurately if not you
may need to adjust the scale on your printer to do this, you'll probably have
to go into the settings and you may need to check your printers documentation on
how to do this, once you've got the document downloaded and you've got the
templates you can then cut all the templates out because the visor section
is bigger than a piece of a4 paper I've designed the visor template to be in two
halves once you've cut the left and right sides of the visor template you
just need to stick them both together
using the templates you can now mark up all the pieces of wood but remember that
you do need two pieces of the outer wall section which is a the more accurate you
are with your marking up that either it will be to follow the lines of the saw
once all the wood is marked up the next thing to do is to cut all the pieces
into the right shape being very careful to be as accurate as you can I'm using a
jigsaw and my bandsaw for more accurate cutting then the next thing to do is to
drill all the holes in parts C and D for the fixing screws and there we go all
the parts are now cut to shape so I've smoothed off all all the flat sections of the wood
because these parts here gonna be where the plastic sits on top and if these are
nice and smooth when the plastic is formed down on top of them there'll be less
distortion in the plastic, it's especially important on the headband
form because on this part if it's nice and smooth you'll get a much nicer form
on the section which goes across the headband which will make it much more
comfortable to wear it's also important to sand down the edges on Part A on both
parts because these are the parts where the plastic is going to bend down so if
these parts are really sharp it could actually split the plastic so I've
sanded these down with a little bit fine sandpaper so both parts a which are the
outer wall sections they need to be about 40 to 50 millimeters in
depth so my ones here are exactly 45 millimeters and the headband section
part which is B needs to be approximately 28 millimeters in depth
Part C and D which is the base plate and the nylon strap holder these need to be
about ten mm in depth the thickness of these two
parts isn't critical I just used some 10 mm plywood that had laying around, so
the plastic I'm using here is not 0.5 millimeters PETG so you can cut them as
rounded rectangles or standard rectangles the idea of rounding the
corners off is just to make them safe so there's no sharp edges but if you do
this you must do it before you form them in the press now I'm not sure but I
think you maybe I'll get away with 1 millimeters thick PETG and I've
enlisted to help with my two boys to help cut the plastic so the next things
there is to assemble the parts together. So get the two large sections which are
A and get the headband form which is B and then sandwich them all together I
find the best way to do this is put them in the vise, when they're in the vise
make sure they're all nice and level, and also I've designed the parts of there
should be a little bit of an offset here about 2 or 3 mm if there's not on
yours and you might need to sand it down slightly. Okay so once that's done now we
can lay the base plate on top just make sure the opening here lines up with the
opening of the headband form and when you lay it on top just make sure they
sits just behind the edge of the headband form as shown here, next I'm
using some 1 inch screws to screw the base plate down next you'll need a
couple of straps which are approximately 35 millimeters wide I'm using some
straps off an old tie-down ratchet but you can use some straps off an old
shoulder bag or rucksack it doesn't really matter as long as they're quite
strong but they do need to be around 700 millimeters in length the next thing to
do is screw the strap support bracket D onto the base plate C first make sure
all the corners and the edges line up nicely and then just screw it down just
enough to leave a little gap so that the straps can feed through the back the
next thing we need to do is to screw the bracket down but we need to make sure
both straps are lining up with the inner edges of Part A the next thing to do is
turn the form on its side and we're going to cut two slots in the base plate
for the straps to go through so first we need to line the straps up with the edge
of Part A and Mark about 3mm past that point you need to do this on either
side then once you've done that you can just get a saw blade and then start
cutting the slots
if your straps are quite thick like mine you might need to go through with a second
blade like the blade on a jigsaw and they go both slots are now done!
The last thing to do is to make the forming strip you can use anything for
this as long as it's flat and strong but it does need to be 25 millimeters wide
I've used a bit of Aluminium flat bar that had lying around a workshop to get
my Aluminium strip to the right shape I bent it over the headband form if you
plan on making a few of these then it's a good idea to put handles on the end of
your strip and that'll prevent getting your hands really sore. Okay so before I
make the first visor I just need to make a little pencil mark on the top of this
wall here of 35 millimetres okay so now we've got our guide line and I put the
straps back on to the form we now need to get our piece of plastic the longest
side goes over the form we need to feed it under the straps up to the line that
we just made and then pull the straps nice and tight, Just make sure the
plastic is sitting evenly over the form and you've got an equal gap both sides then
pull the straps really tight and then use some general-purpose clamps to clamp
them in place. So before we heat the plastic it's a good idea to have your
forma strip to have because there's gonna be a very short window of when the
plastic is hot enough to form and we need to pull the form down onto it so to heat
the plastic up I'm using a basic heat gun here you can buy these in any DIY stores
but at the moment you probably have to buy them online. right so now I'm ready
to heat up the plastic and form the visor now you need to make sure you give
it equal heat across the form and then you'll find that the plastic starts to sag
slightly into the middle then what you need to do is you need to give it a
little bit more time and then grab the forming strip and press it down onto the
form right let's go
so as I mentioned it's important to give the press that equal heat over the form
and slowly you can start to see the plastic start to soften and sag
slightly in the groove section here I'm touching the plastic very quickly of my
fingers just to check how soft it is, it's a very similar process to vacuum forming
when you have to wait for the plastic to be at the right softness and then as
soon as its ready quickly grab the forming strip and pull it down into the
groove to form the shape so it doesn't take very long to cool down and then all
you need to do is release both straps on either side of the form pull the visor
out and then if you can get some 18 or 25 millimeter elastic and sew it into
a loop just put it around the headband section like that and there you go if
you don't have an elastic strap at all you can use maybe a hairband or just a
simple elastic band once you get the hang of making these you could literally
knock out hundreds in no time at all I've worked out it takes roughly 40 to
50 seconds to make each one and if the plastic pre cut that's approximately
70 to 80 visors an hour compared to one an hour on a 3D printer, I already plan
to drop up the ones I've made to local healthcare organisations who desperately
need them and I'll be trying to source more plastic to make more, although
the plastic is becoming more difficult to get hold of so if anyone knows where
you can get the plastic from please leave a comment down below or send me an
email and if anyone has any ideas for maybe an off-the-shelf elastic headband
strap instead of having to cut them and sew them that would save a lot of time
so please send me a message or leave me a comment down below - I think the
Corona virus is going to hit some of the poorer countries really hard so being
able to make these in seconds rather than hours I think it's going to be a
great help. Thanks again for watching and I really appreciate if you could share
this video to get this design out there to people who may be able to use it and
make lots of visors in the fight against Corona virus, that's all for now if you
subscribe to the channel I'll keep you posted on how it's all going and if you
need to contact me you can use the email address on the contact us page on my
website, thanks again for watching and I'll see you all on the next video!