Emergency Use PPE

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Project :: COVID_Aid[edit]

There is a shortage of PPE (Personal Protective Equipment). What can we do for the good of the cause?

These are the models that are in current production:


Printing Farm[edit]

This is a rundown of the machines we're using.

Research & Brainstorming[edit]


  • Continue to research best practices when creating PPE.
  • Continue printing latest revision.
  • Contact Individuals in local healthcare to assess for specific needs.
  • Donating to areas of need.

Areas of Need[edit]

Amount Needed Organization Contact Delivered
Riverside Shore Memorial Hospital Shaun O'Shea 50 Masks; 82 EarSavers
- Accomack County Public Schools Chris Holland 100
- Northampton EMS Laurie Collins 42
50 M, 20 L Accomack EMS C Ray Pruitt 0
Peninsula Regional Medical Center (PRMC Salisbury) - 0
12 M, 4 L Atlantic VFC Cindy Smith 0
20 M, 20 L Oak Hall VFC Cindy Smith 0
? Richmond Area EMS Ms. Justis 0
10/10 Salisbury Area Physicians Tammie Matthews 0
? Hermitage on the Eastern Shore ? 0
? Intrepid Healthcare ? 0
3D Printed Prosthetic Hand

3D Designs[edit]

    • MakeTheMasks.com
    • 3D Face Shield v3 - Full Face Shields. Would need a lasercutter for the shield part.
    • Reusable 3D-printed face mask - This is a re-engineering of the Montana Mask. This might be our new mask! It is designed for three sizes, all of which use the same sized filter.
    • 3dprint.nih.gov - The NIH 3D Print Exchange provides models in formats that are readily compatible with 3D printers, and offers a unique set of tools to create and share 3D-printable models related to biomedical science.

  • Printing plastic bow tie strap clips to make elastic adjustable. Small Strap Clip
  • Started printing 1.2 version of the filter piece. It has a flange and holds itself in place better.
  • March 30 - 12 masks -> Riverside for fitting tests (6 regular and 6 medium)
  • April 3 - 36 masks -> Riverside
  • April 15 - 60 masks -> Accomack County Food Service

Crowd sourcing![edit]

Avengers Assemble! Would you like to help? If you have a 3D printer, these are the models we're currently printing.

As folks join the cause, follow their progress here!
left thumb

Thank You!![edit]

Thank you to everyone who has helped make the project come together! Whether it is organizing meeting places, contacting places in need, or donating supplies, it is all appreciated! Shaun. O'Shea, Chris Holland, Karen Rudder, Karen Prengaman, Scott Snyder, Stephanie Zodun, Jim Goldstein, Angie Melick, Laurie Collins, Cindy Smith.

Engineering Log[edit]

May the 4th Be With You[edit]

  • 3 FlashForges going strong, producing Ear Savers
  • 2 MakerBots going strong producing Masks. (4 at a time)
  • 1 MakerBot is down. The print bed is either warped, or there is an obstruction. Might need a new build plate. More investigation is needed.

April 24, 2020[edit]

  • Six printers still going strong.
  • We're almost out of colored filament. I'm re-configuring all of the print beds. These are my goals
    • All remaining colored filament will be switched to producing the filter squares.
    • Black filament will be used just for the mask portion. This should give us a more uniform look, and a bit of variety with the remaining color.
    • I want to reduce the print time. As of now, it takes roughly 5 hours per mask.
    • We're starting to experience some warping. I want to tweak the settings to also increase reliability of the prints.

April 23, 2020[edit]

  • Used our first 200 yds of elastic. That's roughly 200 masks worth! 400 yds are on the way!
  • Delivered 42 masks to Northampton EMS

April 15, 2020[edit]

  • All six printers have been going strong. Producing a combination of masks, filter pieces, and a few new spool holders so each printer can hold two spools for quick change.
  • Delivered 60 masks to Accommack County Food Services

April 10, 2020[edit]

  • DaVinci Mini Spool Reset Project - I was partially successful. I have successfully reset a spool once. Made a few test prints with ok results. I hit a snag..for some reason, the printer is trying to print the same test print, regardless of what I send to it. In order to get this working, I had to use the NFC on an android phone to reprogram the spool's chip to reset it to its original length. The downside is that neither the printer nor the computer sending the job can be connected to the internet, or the software will blacklist the spool. This is more trouble than its worth. Next, we're going to try swapping out the motherboard on the DaVinci Mini and give it a personality transplant with a RAMPS board.
  • Thank you Mr. Snyder for donating 10 masks! The best quality we've seen, I might add! You rock!

April 9, 2020[edit]

  • Six printers online! (Replicators 1-3, and FlashForge 1-3)
  • Just printed the last of the old filament, and switched over to the new batch. Thank you Mr. O'Shea!
  • Manually cleared jams from FlashForge 1 and 3.
  • Rewired a power adapter to get FlashForge3 running.
Adapted Adapter

April 8, 2020[edit]

  • Jen Kinard (948594) has 20g marine grade polyvinyl clear. 54" x 10-12 yds
  • ACPS Food Services
    • 3 @ Tangier Comb - White
    • 4 @ Chinc Elem - Blue/Yellow
    • 10 @ AHS - Black/Red/Gold
    • 4 @ MES - Blue/Yellow
    • 3 @ NMS - Blue/Red
    • 5 @ KES - Blue/Yellow
    • 4 @ PES - Blue/Yellow
  • Mike Tolbert (942785) for Custodians (Keith Godwin)

April 7, 2020[edit]

  • Testing out some new print settings on the Replicators. Going to try to get a quality that is closer to the FlashForge.
  • Switching from rafts to brims for better plate adhesion...now its too good. Adding space between the brim and the model.
  • Printed 3 new mask prototypes from Rowan University, a Large, Medium, and a Small. In general they are larger than the Montana Mask, though they all three use the same sized filter piece.

April 6, 2020[edit]

  • Thank you David Sabatino, for offering to help with supplies!
  • FlashForge - one running smoothly, and two on the workbench.
  • Makerbot 1/2 - smooth
  • Makerbot 3 update - Well, I don't think the problem is the age of the filament. The Makerbot Orange filament is also producing flimsy mask. Occam's Razer is pointing to the Makerbot itself. Adding it to the cleaning queue, and switching to smaller prints until its quality is improved.
  • DaVinci Mini - The USB programmer is set for delivery today. Follow this project here!

April 5, 2020[edit]

Filament waste from rafts, supports, and failed prints.

Wow! I'm overwhelmed with the positive feedback from this project! I really appreciate the good vibes. It's what we all need right now! Thank you Mr. O'Shea for keeping us going with supplies and coordinating drop-offs!

  • Welcome to the project, Stephanie Zodun and her crew (both at home and at ESCC!) After reading the article, she reached out and offered to employ the expertise of her daughter in printing masks from home!
  • Welcome to the project
  • FlashForges - no change
  • Replicator1 & Replicator2 - All good
  • Replicator3 has started showing some anomalies.
    • It started with some flimsy prints coming off. I could easily crush them with one hand. My first thought was the filament was from the very first batch the school had purchased. Does filament have a shelf life? (Sounds like a good research question, eh?). Light green generic filament was changed out for Makerbot Orange.
  • DaVinci Mini - Proprietary spool problem. The USB programmer should arrive tomorrow. This will allow me to program the board to reset our spools. This will allow us to bring two more printers online.
  • We're going to experiment with recycling our waste filament. To get started, we're going to try the Filastruder! More on that here!

April 4, 2020[edit]

  • Welcome to the project Mr. Snyder! He's going to use his Ender3 to help!
  • FlashForge1 is majorly jammed. It's time for maintenance on the farm, before they all jam hard!
  • FlashForge2 is running nicely
  • FlashForge3 is in need of a power supply.
  • Replicator1 is running nicely
  • Replicator2 is running nicely, though starting to show slight curling.
  • Replicator3 is running nicely.
  • DaVinci1 is in R&D.
  • DaVinci2 is at school.
  • Form2 is at school, in need of upkeep. Needs:

April 3, 2020[edit]

  • Delivered 36 masks for Riverside Hospitol.
36 masks ready for donation

April 2, 2020[edit]

  • The printers have been running smoothly. I got three packs of weatherstripping, and 200 yds of elastic. We're gonna be good on elastic for a while. It takes 36" of elastic per mask.
  • Weatherstripping is still the bottleneck. It takes 18" for a regular mask, and 16" for each medium sized mask. So one pack will be enough for roughly 12 masks.
  • This is the weatherstripping that works the best (D-Section, 5/16" W/ 1/4" T, 17ft L, Black)
  • I just tried to buy 3 more of the weatherstripping, but it says I've already purchased the maximum...I've never seen that error before...worst case, maybe we can circulate the link and see if we can get some donated?

April 1, 2020[edit]

March 30, 2020[edit]

  • Replaced painter's tape on replicator3. Curling had raised the tape from the bed.
  • FlashForge1 - had to modify spool to go around a floor lap to keep the spool at a good angle as it feeds the printer.
  • Making a list for Lowes o.O

March 29, 2020[edit]

  • MakeTheMasks.com - Montana Mask has been upgraded to version 1.2, which includes a flange on the filter. Much improved! Printing out sheets of replacement squares.
  • FlashForge2 is running at roughly 80% efficiency. Some problems with build plate adhesion. AquaNet to the rescue!
  • Finished Sanding/Washing
  • Applied weatherstripping to 12 masks. Printed instructions.

March 28 2020[edit]

  • Replicators 3/3; FlashForge Finder 2/3; DaVinci Mini 0/1
  • Sanding and washing 60 masks. Prepped for sealing strip.
  • Made a new print bed with two masks each for overnight printing on Replicators1, 2, and 3.
  • Going to print some hands free door handles
  • TroubleShooting FlashForge3
 * Extruder motor seems to be slipping.  Need to disassemble and inspect.
 * No Power supply.  Takes 24V(center-).  I accidentally brought the 2nd DaVinci Mini PSU, but it is also 24V.  
 * Need to test to make sure it's center-.  If so, create an adapter to work with the FlashForge
  • TroubleShooting DaVinciMini
 * Proprietary spool chip falsely reports end of spool, creating lots of wasted filament.
 * Going to reprogram the EEPROM to "reset the odometer".
 * Printed out base to hold circuit board.
 * Ordered a prototype board. 

March 27, 2020[edit]

  • Replicators 3/3; FlashForge Finder 2/3; DaVinci Mini 0/1
  • Some filament tangles caused a few failed prints. (Think backlash when casting)
  • Started printing external spool holders for each printer to accommodate 3rd party filaments.

March 26, 2020[edit]

  • Replicators 3/3; FlashForge Finder 1/3; DaVinci Mini 0/1
  • Cleaned FlashForge1 and FlashForge2. FlashForge3 seems to be having motor issues. Need to investigate.
  • Replicators1, 2, and 3 have all been workhorses.
    • Had some problems with stringing. Modified print file, extruder retraction (.5 mm -> .6 mm), and extruder temperature (200 C -> 195 C)
    • Print times didn't line up with my root canal, so the printers went idle while I was out.

March 25, 2020[edit]

  • Replicators 3/3; FlashForge Finder 1/3; DaVinci Mini 0/1
  • Researching how to manually clean FlashForge Finder Print head.
  • Checking into feasibility of printing and creating full face shields. 3D FACE SHIELD V3

March 24, 2020[edit]

  • Setup a 3D printing farm to produce these masks.
  • Replicators 3/3; FlashForge Finder 1/3; DaVinci Mini 0/1
  • Printed out first prototype on a Flashforge Finder. Took 3:40 minutes to print the mask itself, and 30 minutes to print the filter insert.
  • Printed 1st prototype at full size. Perhaps a bit big for the average adult.
  • Print @ 90% - Might be a better fit for most people.
  • Print @ 85% - Good for children
  • Planning to setup printing farm to increase productivity.

Setup three makerbots, and two FlashForge Finders. The three makerbots are estimating a 90% sized mask at 2:09 minutes for a complete mask.

  • The two FlashForge's have clogged nozzles. Need to clean them and try again.
  • Replaced tape on Makerbot Print Beds
  • Had to manually calibrate Replicator2 to combat "Homing Errors"

March 23, 2020[edit]

A few doctors designed a 3D printable filtration mask that can be used in conjunction with a common surgical mask. The mask is printed with PLA, and designed to be washed and reused, but not shared.