Corona virus
Igus produces headbands for face shields
To protect medical personnel, private individuals and companies around the world are currently using 3D printing to produce face shields, among other things. Igus has turned its attention to a central problem in production and is donating the first 100,000 injection-molded headbands.
In order to protect doctors, nursing staff and other people who work directly with patients, 3D printer manufacturer Prusa has developed a face shield and made the design available online for free download. The aim is to produce the so-called "face shields" on as many 3D printers as possible. The project is already considered a success: individuals, maker networks and companies around the world are getting involved and additively producing the face shields. And initiatives such as "Operation Shields Up!" in the USA are bringing volunteers together on their platforms. Igus is participating in this global collaboration and is relying on the advantages of the injection molding process.
Mass production of face shields through injection molding
The design of a face shield is extremely simple: a 3D-printed plastic carrier holds a replaceable plastic film that shields the face. The face shields are not a substitute for a face mask, which is also worn. However, they do provide additional protection, especially for the eyes. They also reduce the natural reflex to touch the face and thus come into contact with the pathogen.
Despite the simple design, one key challenge remains. "Several makers have asked us whether we, as a tribo-filament manufacturer, can provide them with material for this," says Tom Krause, Head of Additive Manufacturing at Igus, looking back. "However, this does not solve the main problems: Manufacturing the headband as a central component is comparatively expensive in the 3D printer and takes more than two hours. This means that only a few parts can be produced per device per day."
Igus therefore relies on the advantages of another process, injection molding. The material used is recycled Iglidur A200. Dr. Thilo Schultes is head of toolmaking and says: "With an appropriate tool, over 10,000 headbands can be produced and delivered per week in the Cologne factory. This enables us to mass produce the headbands quickly and at significantly reduced costs."
Igus manufactures the tool at its own expense. The first 100,000 headbands are available free of charge, after which they are available at the manufacturer's cost. If net proceeds are generated, these will be donated. as
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