Key Parts

Visor Main Structure

There are many different designs for 3D printed visors out there.

At present, we're recommending the prusa RC3 design which, although a little slow to print (there's quite a lot of material to it compared to other designs we've seen) it has the following benefits:

  • it's extremely robust, so we're more likely to "win the war" since fewer will break or be discarded
  • For the same reason, it feels more solid - making the HCPs using it feel more confident in themselves and in it
  • it's well tested in terms of its ability to be cleaned (tests here)
  • it's adaptable to the user for great comfort (more info coming soon!)
  • has strap anchors which are perfect for our 'resistance strap' so the straps are easily sourced and replaced in medical environments
  • Has an optional 'closed lid' (like a cap for the open space above the eyes) for environments requiring that.

The instructions with latest cleaning and test data are available on the Prusa website.

Visor Shield

Prusa recommend using acetate sheets, like for overhead projectors. You need a 3- or 4- hole punch to mount the acetate onto the studs.

We suggest, if possible, using 240 micron thickness sheets or above. Thinner acetate will work, but the bottom shaper holds on less effectively, and the whole thing tends to flap around a lot, which we're concerned will increase distribution of airborne contaminant.

Bottom Shaper

We think it's a good idea to use the bottom shaper component as well as the main visor. It keeps the acetate in the right form all the way down and helps to enclose the face well.


We recommend making straps either from silicone band, which is wipable, or from resistance band available from orthopaedic departments or physios. See our instructions here.

Tools Required

  • A 3D printer. Prusas are really excellent. Second best seems to be the Creality range, although these are a lot more basic, so expect to do a lot of setup and tweaking, and expect printing to go quite slowly. Beyond that it gets a little intense - Tom is using a Wanhao Duplicator i3 to build these visors and it's requiring a lot of nursing.

  • General toolkit for maintaining, adjusting and servicing the printer (screwdrivers, hex keys, etc)

  • A 3 or 4 hole punch (the prusa visors have versions for either) for the acetate sheets

  • Scissors for cutting resistance band.

Materials Required

  • Clear Acetate sheets, A4, >=240 micron thick. We suggest supplying several per visor so they can be disposed of if coughed on.

    In a perfect world, if you can source it, use clear 0.5mm PETG (plexglass) for the visor. Fancy and very solid.
  • PLA or PETG filament, 1.75mm. Depending on your printer and slicer you'll need about 65g of material per visor.

    PETG is preferable because more cleaning options are available but lots of printers struggle with printing it. Unless you *know* your printer can do PETG, stick with PLA.
  • Plumber's silicon O-Rings. Use two large (approx 20mm I.D. like these) and two small (approx 4mm I.D. like these) per visor.

Always Supply Spare O-Rings / Bands! It's so easy to get hold of tons of these, it's best to supply visors with a lot of spares so that if they break while cleaning, or get corona gunk on and need to be discarded, that doesn't leave the visor useless.
Can't get O-Rings? You can use non-catch elastic hairbands, available by the thousand, like these.