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Nottingham engineers produce certified 3D printed face shields for NHS

Wednesday, 29 April 2020

Engineers at the University of Nottingham have designed a PPE face shield with CE approval that they are 3D printing at scale for healthcare workers to use in the fight against COVID-19.

Using the latest in Additive Manufacturing (3D printing) technology and materials at the University’s Centre for Additive Manufacturing, and working with external collaborators, the team will deliver 5,000 of the face shields to Nottingham’s NHS and community healthcare workers.

Building on an open-source design of headband originally from HP, the team in the Faculty of Engineering made modifications to ensure the face shield could pass a regulatory test1 by BSI, the UK’s national standards body, to meet its essential health and safety requirements which ensures the highest level of protection is provided.

The face shields successfully passed the BSI tests and are CE approved1 for use as part of PPE for healthcare workers’ protection against COVID-19 in both hospital and community environments. They are provided in packs to the NHS, with five replacement visors per face shield as well as instructions for use.

The team have made the design and its accompanying documents ‘open-source’ to enable other manufacturers to produce the face shields – however, manufacturers will need to submit their product for testing to the BSI to obtain their own CE certification.

Our primary goal was to ensure that we delivered a PPE solution that was safe and certified so that healthcare workers can have confidence in the equipment they’re using.
Professor Richard Hague, Director of the Centre for Additive Manufacturing

Professor Hague continued: "Using the flexibility of Additive Manufacturing (3D Printing) and laser cutting technology, we’ve been able to arrive at a design, get it tested and approved, and then manufactured and delivered in a very quick timeframe.

“We have also had incredible support from our collaborators in getting these face shields to the NHS – the teamwork and willingness of people to help has been truly heart-warming and we are all extremely proud to be able to contribute to the nation’s fight against coronavirus.”

Professor Donal McNally, Head of the Bioengineering Research Group in the Faculty of Engineering, said: “Having a PPE solution that meets National and EU safety standards is critical for deployment within the NHS.  It has been a truly outstanding achievement to go from nothing to thousands of devices being used by local doctors and hospitals in less than a month.  This would not have been possible without the extraordinary efforts of local manufacturing partners and BSI.”

We are extremely grateful to the University of Nottingham for developing and supplying the visors which will make a real difference to thousands of healthcare staff working on the frontline of the coronavirus outbreak. Packs of the face shields have already been delivered to local GP practices, and we have plans in place to share them with a range of other keyworkers such as people who care for others at home. I think this is a really positive example of talented professionals working across normal boundaries in order to support our local communities in what is an unprecedented and very challenging time.
Dr James Hopkinson, Local GP and Joint Clinical Chair of NHS Nottingham and Nottinghamshire CCG

Design modifications were made by the team to conform to the BSI’s PPE regulations in order to obtain CE marking; this involved making the wrap-around visor element wider, as well as other alterations to improve comfort for users. The HP design was chosen by the Nottingham engineering team as it incorporates a cover at the top of the face shield which prevents fluid from entering the eyes from above – deemed critical by healthcare professionals.

The face shield comprises a 3D printed headband, a laser cut PET visor (with anti-fog coating) and is kept in place with a laser-cut adjustable strap. As well as using their own EOS Laser Sintering equipment, the University of Nottingham’s engineering team have been heavily supported by Matsuura UK to produce the 3D printed element, using their HP MultiJet Fusion process. The visor element has been made with the help of local firm, Prime Group, and Nottingham Trent University are now ramping up for production of the laser-cut strap.

We are immensely proud to use our Additive Manufacturing to support the University of Nottingham in the production of their face shield. The safety of NHS and care workers is paramount and the University has shown that it is possible to manufacture PPE at speed with the relevant safety certification. This is a stand-out project which is setting an example for the rest of industry.
Peter Harris, Additive Manufacturing Manager at Matsuura Machinery UK

Professor Nigel Wright, Deputy Vice-Chancellor, Research and Innovation, at Nottingham Trent University, said: “Nottingham Trent University is delighted to be working with the University of Nottingham on the delivery of a safe and certified PPE solution, enabling our healthcare workers to safely carry out their vital work. During these challenging times, collaborations such as these are crucial and significant to the protection of our communities against this virus.”

Face shields are part of the government’s recommended personal protective equipment (PPE) for coronavirus, providing protection to the eyes and face against contamination from respiratory droplets arising from procedures such as intubation, and from splashing of secretions (including respiratory secretions), blood, body fluids or excretions.

Story credits

More information is available from Professor Richard Hague in the Faculty of Engineering at the University of Nottingham, at richard.hague@nottingham.ac.uk; or Katie Andrews, Media Relations Manager in the Press Office at the University of Nottingham, at katie.andrews@nottingham.ac.uk

Notes to editors:

  1. This 3D Printed FaceShield has been approved by BSI to PPE for Healthcare Professionals 2020/403 – Eye protection Technical Specification. BSI Assurance UK Ltd (Notified Body 0086), Kitemark Court Davy Avenue, Knowlhill, Milton Keynes MK5 8PP, United Kingdom.
    This FaceShield is not a PPE device for general use and shall not be used for purposes other than protection against COVID-19. It has been manufactured for COVID-protection only.

Additive Manufacturing (3D printing) techniques continue to evolve quickly and the Centre for Additive Manufacturing (CfAM) (nottingham.ac.uk/cfam) is at the forefront of this research.

The research undertaken by this group spans across both fundamental and applied research.

The next stage of development of this new technology will be to go beyond using single materials (either polymer or metal) and instead use multiple materials – both functional and structural – in unison to engineer highly functional, durable and life-changing items.

Supported by both governmental sources (EPSRC) and industry, the core research carried out within the group is focussed on investigating the underpinning processes, materials and computational methods for multifunctional Additive Manufacturing, giving the potential to move beyond structural applications and create fully functional systems using Additive Manufacturing rather than passive individual components.

The CfAM works closely with business to translate its technology through to commercial use, and has set up its own consultancy company (www.addedscientific.com) to more fully engage with multiple industrial sectors. By working across both academic and commercial enterprises, new opportunities for increasing functionality and adding value to the technology have been created.

The primary goal of the Bioengineering Research Group is to solve important clinical problems. The research undertaken by the group has led to advances in treatments of spinal deformities and injuries, as well as impacted the evolution of day-to-day medical devices we take for granted, such as baby incubators.

Katie Andrews - Media Relations Manager Social Sciences
Email: katie.andrews@nottingham.ac.uk
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Notes to editors:

The University of Nottingham is a research-intensive university with a proud heritage, consistently ranked among the world's top 100. Studying at the University of Nottingham is a life-changing experience and we pride ourselves on unlocking the potential of our 44,000 students - Nottingham was named both Sports and International University of the Year in the 2019 Times and Sunday Times Good University Guide, was awarded gold in the TEF 2017 and features in the top 25 of all three major UK rankings. We have a pioneering spirit, expressed in the vision of our founder Sir Jesse Boot, which has seen us lead the way in establishing campuses in China and Malaysia - part of a globally connected network of education, research and industrial engagement. We are ranked eighth for research power in the UK according to REF 2014. We have six beacons of research excellence helping to transform lives and change the world; we are also a major employer, proud of our Athena SWAN silver award, and a key industry partner- locally and globally.

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