Open Source PPE Project - A report by Benchspace - Benchspace Cork
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Open Source PPE Project A report by Benchspace.
A National
Crisis
Witnessing the challenges Face shields are an essential component
facing other countries during the of PPE for healthcare providers treating
emerging COVID-19 pandemic patients with confirmed or suspected
COVID-19 infection. In Ireland, this
allowed Ireland to plan in advance
includes the large number of frontline
its response to the crisis.
healthcare workers in COVID-19 testing
centres, community assessment hubs
Shortages of personal protective equipment
and nursing homes.
(PPE) were highlighted as a critical issue
for frontline healthcare staff - placing
In anticipation of the needs of these
these workers at high risk of infection and
healthcare workers, a number of
reducing the ability of healthcare services
manufacturing companies in Ireland had
to save lives. Governments and public health
started developing face shields. However,
officials were faced with the considerable
it would be weeks before these were
challenge of obtaining sufficient quantities
available to the Health Service Executive
of PPE on competitive international markets.
(HSE) for purchase. Because of this, a gap
was expected between the immediate
needs of Irish healthcare workers and the
availability of a reliable supply of PPE,
including face shields.
PPE Report
Open Source PPE Project 01
The Open Source
PPE Project
In the fourth week of March The Open Source PPE project began as
2020, as the number of COVID-19 a collaboration between these two groups.
cases in Ireland passed 1,000, We combined our expertise to bridge the
gap between the immediate needs of Irish
several organisations in Cork were
healthcare workers for face shields and
working to meet the needs of Irish
the anticipated arrival of a commercial
healthcare workers for face shields. supply. To achieve this we were joined by
a coalition of nonprofits, industry partners,
One such group of engineering and
the Irish Defence Forces and over three
regulatory professionals from local
hundred 3D-printing, collection, and
healthcare industries had started
assembly hub volunteers.
prototyping designs and working with
healthcare organisations to test them.
Together these Open Source PPE
At the same time, the staff and members
volunteers built a nationwide manufacturing
of Benchspace - Cork’s shared
network, established three central
manufacturing hub - brought together
assembly hubs, and in just seven weeks,
a national network of 3D printers and
produced over 50,000 face shields for
established a crowdfunding platform
frontline healthcare workers in COVID-19
to finance face shield production.
test centres, community assessment hubs
and nursing homes.
Open Source PPE Project 02
Face
Shields
The engineering, and regulatory experts of the
Open Source PPE team worked closely with the
Quality and Safety Department at the HSE’s
Cork/Kerry Community Healthcare, to identify
Visor Visor
a face shield model for production.
Template Template
The engineering, and regulatory experts of the Open
Source PPE team worked closely with the Quality and
Safety Department at the HSE’s Cork/Kerry Community
Healthcare, to identify a face shield model for
production. This involved infection control assessment,
clinical approval and in-the-field testing of several
models. From this process the Verkstan face shield
design was initially selected.
Throughout the project we received regular feedback Verkstan Face Shield a Face shield
on the performance of these face shields. This led us to
switch to an alternative design on Day 12 of production.
• Open source design developed by • Open source design developed by
This newer N3DPS face shield had a larger gap between
Swedish company (3DVerkstan) UK’s National 3D Printing Society
the user’s face and visor, providing more room for wearing
• https://3dverkstan.se/3dvfaceshield-och-den- • https://national3dprintingsociety.co.uk
face masks or glasses and reducing fogging. The visor
otroliga-kraften-inom-3d-branschen/ /medical-am-covid-19/
attachment to the frame was also more secure.
• 2 components: 3D printed frame • 2 components: 3D printed frame
& A4 Size Clear Visor & A4 Size Clear Visor
Open Source PPE Project 03
3D Printers
Unite
A Micro-Factory Network. volunteer was just 10 years of age.
Many came from Ireland’s engineering
As stay-at-home restrictions community; after Engineers Ireland
promoted the Open Source PPE project to
were introduced across Ireland,
its members. As the network expanded, it
we opened a national campaign
was joined by volunteer organisations with
to recruit volunteers with access access to large numbers of 3D printers.
to 3D printers. These included schools, libraries, institutes
of technology, universities, industry and
This began with a simple social media call, the Irish Defence Forces. Where these
reaching out to Ireland’s maker community. organisations could not participate directly,
It soon grew to include local and national they generously loaned their 3D printers to
newspapers, alongside radio and television volunteers in the network instead.
coverage. In the first few days of the
Instagram and
campaign, 80 volunteers signed up to Many volunteers went beyond 3D printing Facebook call out
participate in our micro-factory network. to provide online technical support, develop to Ireland’s maker
This increased daily, to a network of over our website, coordinate the national community.
300 volunteers nationwide. collection service and establish assembly
hubs. The Open Source PPE project
The majority of these volunteers were could not have happened without their
individuals with home-based 3D printers. contributions.
They included hobbyists, professionals,
students, and families. Our youngest
PPE Report
Open Source PPE Project 04
05
Printer
Recruitment
Map
Volunteers with 3D printers from across the
country signed up to help. Many were searching
for opportunities to contribute PPE to the national
COVID-19 response but were unsure of what to
make, or how to get it into the hands of healthcare
workers who needed it. The Open Source PPE
project tied all of these pieces together and made
it easy for anyone with a 3D printer to get involved
and contribute. We supported each volunteers
with an online technical support community and
a production tracker where they could easily follow Day 1-3 Day 4-7 Day 8-14
and compare their contribution to the project.
Printers
90
80
70
60
50
40
30
20
10
Day Day Day Day Day Day
1-3 4-7 8-14 15-21 22-28 29 Day 15-21 Day 22-28 Day 29
06
Timeline Day 0-27
2800
2450
2100
1750
1400
1050
700
350
0
Day 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Covid 19 New Cases New Frames Printed
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
Day 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Covid 19 Total Cases Total Frames Printed
07
Timeline Day 27-54
2800
2450
2100
1750
1400
1050
700
350
0
Day 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Covid 19 New Cases New Frames Printed
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
Day 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
Covid 19 Total Cases Total Frames Printed
08
PPE Events and Media Day 0-54
Blood Bike Services & Switched Irish Defence
Southern 4*4 Response Online
production to Forces Assembly
start national collection Production
N3DPS Hub opens
of frames from printers Tracker v2
at Collins
Call for Open launched
Barracks
Source PPE
Volunteers
HSE Request
on Instagram
Support from
Irish Defence Echo Live
Go Fund Me Forces for PPE RTE National Twitter Micro Tipperary Live
Article
Launched project News Factories
Twitter Irish
Volunteer
Defence Forces
Assembly
96FM Interview Hub Opens at
Garyduff Sports
Centre
Day 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Volunteer Travel restriction Announced
52,023
Assembly extended to 5km from home
Hub opens shutdown of
at Limerick 3D printing
operations Total Frames
Institute of Printed
Technology to printers
RTE National
News
Irish Tech News
Day 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
PPE Event Media
09Printer Resource
Statistics Statistics 52,023 Total Frames
Printed
Frames Frames
3D Printer Filament
244 4 1,040KG 1,040KG 343 km
individual individual
0-250 1,000—1,250 Cork Belfast
printers each printers each
completed completed
343 km
35 1
individual Estimated total weight Estimated length
250-500 individual 1,250-1,500 of filament used (kg) of filament @330m (km)
printers each printer
completed completed
Print Time Visor Material
Estimated total Estimated area of visor
16
of print time material used (sqm)
2
individual 500-750 individual 1,500-1,750
printers each printers each
26,012
completed completed
HOURS
2.97
6,489
4 1
individual 750-1000 individual 1,750-2,000
printers each printer 1,084
completed completed
DAYS YEARS
10Nationwide
Collection Team
Two voluntary groups, Blood Blood Bike South
Bike South and Southern 4x4 Blood Bike South is an out-of-hours urgent
Response took on the challenging medical transport service, part of a national
task of organising a collection and network of Blood Bike Groups (Blood Bike
delivery service for the hundreds of East, Blood Bike MidWest, Cú Chulainn
Blood Bikes and Blood Bikes South
stay-at-home members in our 3D
East). Coordinated by a Blood Bike South
printing network.
volunteer, this national network contributed
to the Open Source PPE project while
Within just a few days they had implemented
simultaneously maintaining the out of hours
a nationwide logistics service, coordinating
services they provide to public hospitals on
with the National Blood Bike Network,
a daily basis.
Bike Marshalls and Bravo Charlie Tango
motorcycle volunteers where necessary.
Southern 4x4 Response
Between them, these teams collected face
Southern 4x4 Response comprises a
shield frames from volunteer printers in every
group of trained and vetted 4x4 owners
corner of the country and delivered these
who offer severe weather and off road
to central assembly hubs. Many of these
transport to support emergency services
collection teams were on the road seven
and communities in Cork and Kerry. Their
days a week, often at their own expense.
drivers visited printers two to three times a
To help us manage this national collection
week and like so many volunteers around
service, one of our volunteers built a website
the country who helped neighbours,
to track the quantity and location of printed
relatives, friends and strangers found the
face shields, schedule these for pickup and
experience very rewarding.
organise the resupply of 3D printer filament.
PPE Report
Open Source PPE Project 11Aula Max and independently run by
Assembly volunteers from LIT. These assembly
Hubs
hubs worked together to complete the
final steps of face shield manufacture,
packaging and distribution to the HSE.
Collins Barracks, Towards the final weeks of the project,
Co. Cork. members of the Open Source PPE team
Garryduff Sports Centre, worked with local industry to produce
Co. Cork. injection moulded frames for face shields.
Aula Max, LIT, Over 10,000 of these were also packaged
Co. Limerick. and distributed by our assembly hubs.
Before delivery to healthcare workers,
all 3D printed frames had to be checked
for quality, paired with two clear
visors, and packaged. This work was
completed at three central assembly
hubs. The visors required for this were
cut and processed by Watermans and
Irish On 3rd April the HSE requested the Defence
Forces to assist with the Open Source PPE
Carrig print in Cork, who generously
volunteered their services.
Defence project. In response, they established two
3D printing farms in Collins Barracks Cork
Force
The first assembly hub was established
and the Curragh Camp. These used the
by a team of volunteers from DePuy DePuy Synthes Cork
Defence Forces’ existing 3d printers as well
Synthes Cork and the Garryduff The Corporate Social Responsibility
as additional printers and material acquired
sports centre. This pop-up factory team from DePuy Synthes (a medical
specifically for the project. In total the
was operated 3-4 times per week by devices company in Cork) offered their
Defence Forces 3D printed over 3,000 frames
groups of twelve volunteers. This was logistics expertise to the Open Source
for face shields. This work was carried out
followed by a second site opened by the PPE project to develop the assembly line
by members of the Ordnance Corps and the
Irish Defense Force in Collins Barracks procedures that were needed to clean,
Communication and Information Services
Cork and operated by young soldiers check and package face shields before
Corps. In addition to 3D printing the Defence
whose training had been suspended in delivery to the HSE. They also brought
Forces also built up a logistics and assembly
response to the COVID-19 pandemic. together over 100 volunteers from across
hub in Collins Barracks Cork.
A third assembly hub was opened at their company and the Garyduff Sports
the Limerick Institute of Technology’s Centre to run our first assembly hub.
PPE Report
Open Source PPE Project 12Income
Corporate Donation
Fundraising (Aspen Grove)
and Financial Corporate Donation
(Anonymous)
Transparency Corporate Donation
(Anonymous)
For each Euro donated to the Open Source PPE project we
Public Donations
were able to produce one face shield. These were donated
(GoFundMe)
to healthcare workers free of charge.
We fundraised a total of €50,870 to finance the purchase
of materials needed for manufacture. Members of the
public donated €34,563 to our crowdfunding campaign
Expenditure
and the remaining €16,308 was donated by local
healthcare industries and businesses. Many businesses
also donated their time, services and materials for free.
3D Printer Filament
€16,239
Of the total funds raised, 96.2% (€48,956) was spent on
purchasing raw materials for manufacturing. This consisted Visor Material
of 3D printer filament (31.9%), visor material (59.5%) and €30,288
packaging supplies (4.8%). The total of all other expenditure
was €1,833 (3.6%). This consisted of crowdfunding fees Packaging
(2.4%), website hosting (0.3%), shipping and admin costs €2,429
(0.9%). The balance of funds remaining at the end of the
Open Source PPE project was €81 (0.2%). GoFundMe
€1,234
Website, Shipping & Admin
€140
Shipping & Admin
€459
Open Source PPE Project 13National Efforts ACME Blinds:
10,000 frames
CALT Dynamics:
10,000 frames
Capacity Per Day
Future Plastics: Key Plastics:
10,000 frames 5,000 frames
Benchspace:
1,200 frames
University
of Limerick: Merv Colton: Cartolytics:
5,000 frames 1,000 frames 500 frames
Cork Institute
of Technology:
500 frames
Kinsale
Community School:
200 frames
Fablab Nerve Centre: Shnuggle:
150 frames 25,000 frames
Blocblinds: Sligo Institute
400,000 frames of Technology
Open Source PPE Project 14Achievements and Thanks
I am so proud to be part of a volunteer A testament to the spirit I have heart and lung conditions, and all
effort that sprung up in such a short space of togetherness in crisis. this mess is to protect people like me.
of time. The organisation involved was This project provided me with unique
colossal and the leaders made it look easy! opportunity to contribute, to provide
Huge thanks to the bike marshals for their some help to people who are trying to help.
efforts, chats and positivity. Much appreciated!
Tom English Mark Carr Josip Almasi
Co. Clare Co. Kilkenny Co. Cork
It was inspirational and super well organised. I am very glad to have been able I was the second youngest printer part of
My 14 year old daughter was really happy to have played a very small part in this. And honestly this was probably the
to play a part in helping out. We bought a monumental effort. If in the future most fun I have had in ages, just the sheer
a second printer to increase production, there are other schemes I would amount of knowledge
and will donate this to her school whenever love to be involved.
they go back to school.
Les & Ellie Mahon Paul Howarth Harry O’Connor
Co. Cork Co. Kerry Co. Cork
This project showed the power Our staff were proud to have I’m very proud to have been part of such
of community spirit and what been of some help to the project. a well run, well intentioned group. A very
can be achieved. good memory to have in one of the worst
of times.
Aoife Devlin Tipperary County Council Library Service Mary Lynch
Co. Cork Co. Tipperary Co. Clare
15Project Contributors + 200 Anonymous Printers
Printers
Aaron Barry Darek and Paulina Halka Facebook Cork John O’Connell Miriam Nugent Sean Forsyth
AlanJ Darran Kerwick Fachtna Roe (TCFE) John Walshe Miroslaw Jutkiewicz Sean Smyth
Grange Community
Andrei Calistru Darran Shortt Farivar Kaghazchi (Fa) Jonny Rowan Niall O’Connor
College
Andrei Reaboi Darrell O’Brien Fergus Somers Joris Niall Whitty
Sebastian Knapp
Andrew Cashman David Furlong Fingleton White Josip Almasi Nicolas Wijnstekers
Sgt John Meere
Aniket Latpate Dean Gallagher Finn Yore Karl Grabe Nikk George
Shane O’Donnell
Coláiste Dún an Rí
Aoife Devlin Frank Courtney Ken O’Connell Noel O Flaherty
Simon Kenyon
Derek Farrell
Aoife for CCAE, UCC+CIT Gaetan Meister Les & Ellie Mahon Paddy Fagan
Fire1Foundry Stefan Bondorf
Ben Lenihan Garry O’Mahony Leslie Simons Paddy Foley
Dermot Saville Stephen Martin
Bob Finley Gavin Pay Lorcan Murphy Patrick Gaynor
Don Kenneally Stephen Moroney
Bryan Alexander Harry O’Connor Mark Carr Patrick Rooney
Donnacha Kelleher Tal Eretz Kdocha
C. Mulder James Temple Mark Gaffney Paul Howarth
Ed Doyle Thomas J. Fleming
Castleblayney Youthreach Jay Bradley Mark McLoughlin Paul Quinn
Eddie Connolly Timothy Buckley
Chris Allen Jeffrey McCormick Martin O’Driscoll Pawel-Donabate
Eimantas Kozeniauskas Tipperary County Council
and Eva McGrergor
Chris Fenlon Mary Lynch Piotr Wieczorek
Library Service
Elise Kenneally
Jens Köpke
Ciaran Patterson Matthew O’Neill Raf Peeters
Tom English
Emmanuel Stone
Joe Fahey
Colin Russell-Conway Michael D. Murphy Rafal Szczepanik
Tomasz Nicinski
Eoghan Lenihan
John Alfred (MeSSO CIT)
Colm Gibbons Richie Cunningham
Tomra
Eoghan Mulholland Adare, Co Limerick
Michael Gargan
Conor Burke Robert Roche
University College Cork
Evan Dargan Hayes John from Gypsy
Michiel DeLepper
Conor O’Neill Scott Phelan
John O’ Shea
Mike O’Sullivan
16Project Contributors
People Ogranisations
Fergus Somers Hyacinthe Jacquet Irish Defence Forces Garyduff Sports Centre CIT Interior Architecture
David Scannell Commuity Outreach Team Blood Bikes Ireland Watermans Printing UCC & UCC Library
Ian Barron Diane Fehilly Blood Bikes South Carrig Print JB Roche
Michiel DeLepper Victor Twohig (T&T) Blood Bike East Engineers Ireland Bike Marshalls
Martin Horgan David Kyle Blood Bike MidWest Aspen Grove Solutions LIT
Sean Walsh Pat Crowley Cú Chulainn Blood Bikes 3D Fuel Bravo Charlie Tango
Alan O’Halloran Martin Lehane Blood Bikes South East Cork City Libraries DePuy Synthes
Deirdre Hourihane Paul O’Brien Southern 4*4 Response CSN College
Sean O’Sullivan Luke Harman
Thomas J. Fleming Michael McLaughlin
Seán Elliott Kevin Geary
Enda Moynihan Ciaran O’Loughlin
Nicky Bent Marc O’Riain
Martin O’Driscoll Gavin Russell
Conor O’Neill Owen Kelly
Bernard Yore Deirdre Breen
Wan Waterman Cathal Brown
Jay Bradley Colm O’Neill
Joe Fahey
Eoghan Calnan
17Thanks
By mid May 2020, the HSE The Open Source PPE team would like
Cork/Kerry advised us that to thank all those who contributed to this
commercial suppliers had begun project. Many had family or friends who
were frontline healthcare workers; many
to meet their demand for face
were cocooning to protect themselves,
shields, and as such we could
and others contributed to this effort despite
wind down our voluntary effort. uncertainty about their own employment
and financial security.
The Open Source PPE project had fulfilled
its purpose, to supply face shields to
The response to the Open Source PPE
frontline healthcare workers until the
project was extraordinary; every request
arrival of sufficient commercial supplies.
for support was met with overwhelming
What had initially been conceived of as
generosity and motivation. That Ireland
a small project, which we hoped could
has such a pool of selfless, skilled
produce 10,000 face shields, had grown
and experienced individuals who will
into a national operation with over
respond to a crisis such as the 2020
300 contributors making 50,000 face
COVID-19 pandemic is cause for pride
shields over a 2 month period during the
and confidence. This was a demonstration
COVID-19 pandemic.
of community, institutional and industry
collaboration at its best.
Open Source PPE Project 18Benchspace Cork CLG Unit O15 Marina Commercial Park Centre Park Road Cork City T12 YAE4 benchspacecork.ie
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