Dow Unveils Open-Source, Lightweight Face Shield Design to Boost PPE Production

Dow, headquartered in Midland, Michigan, has engineered a streamlined, lightweight face shield that can be produced quickly using laser, die, or water‑jet cutting. The design is released as an open‑source file, enabling manufacturers worldwide to ramp up production of this essential PPE during the COVID‑19 pandemic.

In partnership with Michigan‑based tinkrLAB, Dow is producing 100,000 face shields for donation to the state’s hospitals. tinkrLAB handles laser cutting and assembly, and has already completed an initial batch of units.

Although Dow is primarily a leader in polyethylene resins, the company leveraged its Pack Studios development facility in Freeport, Texas to prototype the face shield. Dow also collaborated with value‑chain partners to source a foam comfort strip that ensures a secure, comfortable fit.

The shield features a thick, transparent plastic film and an adjustable strap, complemented by a 9″×1″×1″ polyurethane foam spacer that fits comfortably beneath safety goggles or an N95 mask. The simplicity of the design means it can be cut from a single sheet of material and assembled with minimal tooling, dramatically speeding production.

The open‑source specifications allow manufacturers to use a variety of polyolefin materials. Dow tested a 0.010‑inch thick film made from Surlyn ionomer resins, which delivers the right balance of stiffness and optical clarity while permitting disinfection and reuse.

“Our mission in releasing this design is to empower others to expand production of critical face shields,” said Diego Donoso, president of Dow Packaging & Specialty Plastics. “This collaboration demonstrates how our materials expertise, technical support, and Pack Studios’ rapid‑development platform can help protect frontline workers.”

Melissa Rabideau, founder and president of tinkrLAB, added, “COVID‑19 exposed gaps in our supply chain. As a small business, we can mobilize volunteers quickly, but by partnering with larger firms, we amplify our impact. Our hands‑on approach is in our DNA.”

Prototypes were field‑tested by physicians and nurses, and the final design incorporates their feedback. While most face shields are single‑use, certain film formulations allow for disinfection and reuse, in line with FDA guidance and the Emergency Use Authorization issued during the public‑health emergency.

Manufacturers and individuals wishing to produce these shields can download the design file online. Dow is also seeking partners with film‑manufacturing and cutting capabilities to continue expanding PPE production. Contact facshld@dow.com if you are interested.

The Michigan State Police State Emergency Operations Center (SEOC) manages distribution. Organizations that need face shields should contact their county emergency management office, or submit a consolidated request to MSP-SEOCPSL@michigan.gov.