To aid the fight against Covid-19, Foster + Partners has designed a general-purpose prototype face visor, suitable for cleaning and reuse. It is also specifically aimed at fast mass production.

The firm is sharing the design templates and material specifications as an open-source asset. This is to encourage both designers and large-scale manufacturers to investigate the potential of digital and laser cutting machines as an alternative to 3D printing technology.

Developed by a team of industrial designers, model makers, architects and analysts, the prototype is made up of three components: a shield crafted from 0.5mm optically clear polyethylene terephthalate glycol (PETG), an interlocking soft PP headband, and a surgical silicone rubber head strap that ties the two together. These were all cut on the practice’s digital flatbed cutters by its print room and model making teams. Each visor can be cut from sheets in under 30 seconds and the elements can be assembled in under one minute. With a single cutting machine, Foster + Partners was able to cut and assemble components for 1,000 masks in one day, reducing the time taken to produce 3D-printed alternatives.

Another important advantage is that the masks can be easily disassembled, cleaned, sanitised and reused, addressing the growing shortage of raw materials for visor production. The studio is now delivering these prototypes to several London hospitals where they are being tested. They are also exploring means of getting the design approved for mass production and use by health workers.