Face Shield Designs

Home / ElastiDry Protective Coating / Face Shield Designs

Observations Regarding Face Shield Designs Using Commonly Available Materials

Dace Enterprises effort, the Sandia E-PiPEline Team, systematically evaluated design options for face shields
constructed from commonly available materials (CAMs). This study is not focused on face shields for medical applications, and
as such, has excluded labeling and flammability considerations suggested by the FDA. Design options for face shields were
analyzed with subject matter expert input considering the design’s effectiveness (seal around face), reusability (compatibility with solvents, degree of inertness), producibility (ability to obtain materials, build time), cost, and comfort (fit
around head, contact surface interface). Observations for the design of face shields using CAMS are provided here.


The principle design variables considered for the construction of a face shield were:
Primary shield material: polyethylene, polypropylene, cellulose acetate
Structural material: foams, safety glasses, cardboard, wood
Attachment methods: sewn, glued, stapled

The graphic at top illustrates the results of scoring more than 900
designs evaluated for face shields using CAMs. The normalized
design scores are shown in blue, with the best options shown in
red. The scores are normalized relative to the highest score in
the effectiveness and producibility metrics.


• Minimizing the gap between the face shield and the forehead will help reduce the chance of liquid splash to the eyes
• It is important that the face shield extends down below the chin and stretch around the full-face area
• Designs that use compression to attach the face shield to the face were observed to be promising

• Using foam as the primary frame/face interface material provides splash protection
• For reuse of the face shield, choosing materials that are compatible with common solvents we use polypropylene.