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Penn Health Tech Covid-19 Rapid Response Team - PPE production crowdsourcing: Rivet face shield

A Rapidly Fabricated Reusable Face Shield for COVID19

  • requires laser cutter and riveters 
  • faster construction than 3D printed designs
  • contains no foam or elastics and can easily be disinfected and reused



The face shield is created with two parts: an adjustable headband and a clear plastic shield.  Both parts are manufactured from flat sheet stock using simple 2D cutters, laser cutters, CNC routers and scissors. It is possible that vinyl cutters may work if they can cut through the material.

Two strips are used for the headband, one for wrapping around the head, a second one for holding the face shield off the face.

Rivets are used to fasten the two straps together and the clear shield to the headband. One rivet is also used as a pin to hold the strap as part of a buckle.

A rivet in the band can be used to secure the headband in an adjustable way.

Example Bill of Materials:

Headband (main band, shield mount)

ABS (for 2 parts)

0.03” x 28” x 4”

McMaster-Carr: 8586k873, makes 2 pairs of straps

Clear Shield 

PETG, 0.04”

9” x 12”

McMaster-Carr: 9513k157 makes 8 pieces

1/8” Blind Al. Rivets

1/8 x 1/8"


McMaster-Carr: 97447A020

1/8" Blind Al. Rivets

1/8 x 1/4"


McMaster-Carr:  97447A125

0.067" thick washers for Blind Rivets

0.134” ID, 0.375” OD, 0.057"


McMaster-Carr: 90183A213

Alternate materials: 

clear shield riveted to mounting strap
Clear shield riveted to mounting strap

The headband can be made from almost any semi-rigid plastic. We have tried: ABS, HDPE, LDPE, LLPDE, PETG, Styrene and PP.   The polyethylenes don’t cut well with a laser, but can be used with some post processing (deburring/filing); they also tend to be cheaper.  A CNC router or stamping method works better for those. 

The clear shield can be made from almost any clear plastic. We have successfully tried: PETG, PET, and PC. Thicknesses range from 0.02” to 0.05”. As of April 1, 2020, there is a shortage on nearly all clear plastic sheet, especially PETG. 

If the headband is plastic such as ABS cut out with a laser, care should be taken to wipe down or rinse off excess plastic dust that may have been ablated onto the surface. This can also reduce odors.

CAD files

Note: the shield is  designed to be compatible with several headband designs so it has extra holes that can be ignored.

Rivet assembly instructions

This design was created by Terry Kientz at the Penn Engineering Research Collaboration Hub, March 27, 2020. It was debugged and tested by a wide variety of engineers, PERCH staff,  physicians and hospital staff at the Hospital of the University of Pennsylvania (HUP).


These materials/designs are provided "as is" with no express or implied  warranties of merchantability or fitness for a particular purpose or any other warranty (express or implied).  Penn makes no representation or warranty that the use of the materials will not infringe any patent or other proprietary or intellectual property rights of any third party.