This project creates a multipurpose device that protects healthcare workers from liquids and flying fragments, providing whole user safety. Existing face shields are uncomfortable and fail to protect the entire cranium from bodily fluids, while disposable ones are not environmentally or economically viable. The device developed is adjustable, comfortable, reusable, and easy to use, withstanding necessary cleaning processes. It also allows the use of head-mounted tools and devices.

The proposed solution is called the Flip Shield. It includes a head shield, face shield, and hinge mechanism designed to protect against bodily fluid sprays, particularly from coughing and sneezing. The head shield has a slightly enlarged brim, protrusions on either side for the hinge, and can act as a platform for accessory devices. The face shield is designed to mate with the brim of the head shield, a remodelled face shield, and protrusions on either side for the hinge. The hinge mechanism is comprised of two curved hinge slides and two attachment pieces. The attachment pieces move inside the hinge slide, this ensures the head and face shield remain connected while allowing the face shield to move up freely. A prototype was 3D printed using polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) filaments, but production-grade parts will be constructed using polycarbonate and expensive, high-quality, water-cooled tool steel injection molds. The Flip Shield was evaluated based on the set-out verification/validation criteria, cleaning test methodology, and evaluation results, including an easy-to-use design, a locking hinge, reusability, simple assembly and disassembly, the time it takes to put the device on, and weight. Cleaning methodology was also tested, including disinfectant wipes and bleach solution method. Durability methodology was evaluated by performing the durability test, which aimed to evaluate the resilience of the hinge mechanism during everyday usage. The assembly and disassembly test were conducted to assess the duration and ease of each process. Both disinfectant wipes and bleach solution were found to be effective cleaning methods. Assembly took 1 minute and 10 seconds, disassembly took 32 seconds, and the durability test revealed that the PLA material used for the hinge mechanism caused the device to fail after approximately 100 cycles.

The attachment method, material selection, and hinge channel design of the face shield can be improved to enhance its functionality and user-friendliness. Using a stronger material for better attachment and manufacturing through injection molding can result in a higher-grade and longer-lasting design. The cleaning method can be improved by combining the bleach solution and disinfectant wipes. Improving the push button design and modifying the finger tabs for better ergonomics can also enhance the design. A clear and transparent pet sheet with no ripples is crucial for clear vision, and a short user manual with engravings on the design body can guide users for easy installation of the hinge pieces.

The attachment method, material selection, and hinge channel design of the face shield can be improved to enhance its functionality and user-friendliness. Using a stronger material for better attachment and manufacturing through injection molding can result in a higher-grade and longer-lasting design. The cleaning method can be improved by combining the bleach solution and disinfectant wipes. Improving the push button design and modifying the finger tabs for better ergonomics can also enhance the design. A clear and transparent pet sheet with no ripples is crucial for clear vision, and a short user manual with engravings on the design body can guide users for easy installation of the hinge pieces.

The final design solution for the face shield project satisfies all the requirements, including creating an adjustable and comfortable shield, providing space for device mounting, making it reusable, and adhesive-free for easy cleaning and maintenance. The shield is made from durable and high-quality materials, making it cost-effective and eco-friendly. The final design solution is a reliable and effective tool suitable for various users.