Crescent Face Shield Headband

Design ID: Crescent Face Shield Headband V-01

This is a face shield designed for easy and rapid manufacture. The design is listed with the Therapeutic Goods Administration of Australia classified as GMDN Code 64779 and listed under ARTG 337217.

The face shield was designed with the intention of providing health care workers with an interim supply of face shields. It can be cut from a sheet via 2D processes such as laser or waterjet cutter, or 3D printed. Using a waterjet cutter, it and has been tested with 4.5mm polycarbonate (see the face shield Design Summary and Instructions for Use for further detail).

This is a design was inspired by the RC3 shield visor by Prusa and tailored for 2D cutting but can be 3D printed too. This will allow those with 2D cutting assets (such as laser/waterjet cutters or routers) to have a tested design for production (see Testing Report). This was designed by members of the Advanced Manufacturing Alliance @ CDU in consultation with local healthcare professionals. Approximately 160 can fit on a 2.4×1.2m sheet and take 1min each to cut on a waterjet.


  • Overhead droplet protection: Filled in headband
  • Additional wrap-around droplet protection: Altered rear shield mounting points slightly towards sagittal midline of head increasing wrap around distance and decreasing gap between shield and side of face.


  • Option of 3D printed geometry or 2D profile for 2D cutting. 2D cutting allows for scalability, faster production, and use of more durable materials and less pores or cavities associated with layered production in 3D printing.
  • 3D printing option allows for flexible on-site manufacturing.
  • Shield attachment point spacing enables use of EU/AUD standard 4-hole punch for cutting shield (4x 6mm holes, 80mm spacing), enables flexible on-site manufacturing.
  • Shield attachment point spacing enables use of A4 sized shields (210x297mm) so that commonly available transparencies and other plastic sheet material are suitable. Enables flexible on-site manufacturing.
  • A readily commercially available elastic strap is designed to be used to fix the visor to the head. Strap can be bought with buttonholes already in place, which is recommended. Alternatively, holes can be made in the elastic strap, but this may affect life/strength.

Benefits for Sterilisation:

  • Material able to withstand higher temperatures associated with sterilisation: Headband made from solid sheet polymer (Polycarbonate or PETG recommended)
  • Less pores or cavities which are associated with layered production in 3D printing: Headband made from solid sheet polymer (Polycarbonate or PETG recommended)

Fit and use:

  • Reusable provided it is sterilised correctly and meets basic quality checks prior to re-use (see IFU)
  • Interchangeable components- Simple to replace headband/shield/strap if it becomes damaged during use or cleaning.
  • Suitable for a wide range of head sizes
  • Mounting points for overhead strap if required
  • See Design Summary document.
  • Cut from 4.5mm plastic sheet. We have used polycarbonate which was successful, but other materials such as PETG are suitable.
  • For 3D printing PETG is recommended and PLA is acceptable when PETG is not available.
  • If intending to wear for a long period it is recommended to use a sweat band or other cushioning device to increase comfort.

Design modifications by:

  • Matt Harbidge and Rebecca Murray

Design based on design by:

  • Original design by Prusa located HERE.

Other designs

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