Javelin teams up with Sunnybrook Research Institute to develop and manufacture reusable PPE

Article by Conner Janeteas created/updated April 17, 2020

Javelin Technologies Inc. has partnered with Sunnybrook Research Institute to collaboratively develop, manufacture, and rapidly-deploy Personal Protective Equipment (PPE) during the COVID-19 Pandemic for front-line workers across Canada.

3D printed face shield component

3D printed face shield component

The project team has developed a modular face shield, based off an open source design, that has been iteratively modified and tested to ensure the device is compliant with regulatory requirements for working in a hospital setting.

You can help by making a $20 contribution for the 3D printing costs »

Sterilizable and Reusable PPE

In addition, we have placed focus on ensuring the device is sterilizable and reusable to overcome the resource burden caused by single use devices, and ensure the design can be produced with both additive manufacturing and traditional mass-production methods whilst using commonplace materials that are easy to source. The aim of the project is to:

  • Validate sterilizability of 3D printed components to empower a shift from disposable to reusable devices
  • Develop an open-source repository consisting of manufacturing and materials protocols, and sterilization methods and protocols for distribution amongst Canada’s health and manufacturing verticals.
  • Pursue mass-production, with the aim of producing 12,500 shields/week by mid-late April; leverage Javelin’s customer printer network, as well as in-house resources, bridge the gap to production and support injection molding production with additional units
  • Secure funding to manufacture devices at no cost to the healthcare system
  • Understanding the needs, challenges, and results of high-speed deployment of additive manufacturing technologies within the healthcare space; documenting these aspects to develop a set of “Best Practices”

Clinical Feedback and Additional Development

Presently, we have received feedback from the teams in the Occupational Health and Safety, and the Medical Devices Reprocessing Centre, and are continuing to iterate our design with feedback from Infection Prevention and Control. To date, we have: finalized the design for both device components, with clinical feedback from researchers as well as tested in the ER, and confirmed serializability of both components with readily available methodologies. Currently in progress is droplet simulation testing to compare efficacy of our device against other temporary solutions being used. Upon signoff, a final distribution package will be made available via open-source repository. Administratively, we have started the process coordinating device distribution efforts within the GTA, have begun establishing partners in BC, and both project partners have applied for funding from numerous agencies.

Batch of the PPE Face Shield printed parts

Batch of the PPE Face Shield 3D printed parts

Aiming for Mass Production

In addition, we have secured intent to contribute from public and private donors and aim to set up contribution channels through the Sunnybrook Foundation and the Javelin web store. With regards to production, we have been mobilizing Javelin’s customer base and in-house equipment to begin production; to date, we have secured $10,000+ in funding and produced 550 shields for distribution within Ontario. We have also sourced tooling for mass production of both device components, as well as confirmed per-part price, with the intent to kick off production upon final decision from funding agencies.

Assembled Face Shield

Assembled Face Shield

Contribute to the PPE Production Effort

If you would like to contribute to the cost of the 3D printing raw materials for the production of the face shields you can make a $20 contribution via our web store. Note that Javelin is not a registered charity and, as a result, we are not able to provide tax receipts for project contributions.

 

Click to Support Face Shield Production »

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Conner Janeteas

Conner is the Professional Services Manager overseeing the Javelin additive manufacturing team and production facility in Oakville, Ontario, Canada.