Solinear is more familiar with the manufacturing of feature facades not face shields. However, due to the critical shortfall in protective face shields – crucial in the battle against the spread of COVID-19 – some very resourceful members of the Solinear team are concentrating their efforts on 3D printing vital pieces of equipment for the emergency services.
It made sense
The brilliant idea was proposed by one of Solinear’s welders, Elliot Headley, who subsequently discussed his proposition with Andy Moore, Solinear’s design manager. Elliot suggested that “In the current situation, Solinear’s 3D printers could be better applied to the production of face shields.” Elliot continued: “The sooner we can contain COVID-19 the sooner we can take stock, begin to recover, get back to some level of normality. For me, personally, Coronovirus meant that I lost out on one of the greatest adventures of my life – travelling the world – but I’m aware that there are people who have lost their jobs, lives and loved ones to this devastating virus. Having seen the news and understanding the gravity of the situation it made sense to me – switch from production of regular Solinear items to face shields, if we can.”
Revolutionary
The 3D printers were originally purchased for the manufacturing of adaptable ancillary components for Solinear’s architectural louvres and solar shading products.
Before the introduction of the printers and the fabrication of the items, certain projects were proving troublesome resulting in unproductive time and frustration, rejected products and therefore wasted resources. 3D printing, with its pinpoint accuracy, revolutionised production thus making potentially awkward louvre blade installations easier, speedier and more efficient for Solinear’s busy fitters who are deployed to sites all over the UK.
3D printing explained
3D printing (also known as rapid prototyping or additive manufacturing) is a process that fabricates a three-dimensional object from a computer-aided design model. Typically, the object is formed by means of a robotically controlled syringe continuously adding material layer by layer, hence the alternative name ‘additive manufacturing’. 3D printed items can be produced using minimal material, reinforcing the structure with a complex framework, thus creating a product that is lightweight whilst retaining strength and integrity
The 3D printer constructs objects from a spool of plastic, commonly polylactic acid or polylactide (PLA). While PLA is the most frequently used plastic, and Solinear did use it early on, PIPG (recycled PETG commonly used to make water bottles) is favoured as it has better impact strength compared to PLA, is more resistant to chemicals and can easily be sterilized.
Solinear showcases 3D printing
Solinear’s enthusiasm for the latest technology was showcased at Smart Factory Expo 2019 providing an insight into how the business is embracing 3D printing.
Andy Moore, who attended the event explains “I extensively researched the various options available and we purchased our first 3D printer in August 2019. After exhaustive (and some entertaining!) testing of durability and experimenting with a variety of designs and printing materials, we began production of our unique and exclusive components. As a result, Solinear was invited to appear at Smart Factory Expo – we demonstrated how, with the help of 3D printing, we overcame the challenges of fitting pre-cut sections of our profiles to buildings where the design differed from its built state.”
Andy continued “Never in my wildest imagination would I have thought that just a few months later I would be involved in the production of face shields to help defend thousands of people from a pandemic.
We had only just purchased another printer to step up production when lockdown was imposed. A few days into lockdown, Elliot contacted me with the idea, and I agreed – we could do this! I can even control the printers remotely and set them going.
The Solinear team had already requested their own 3D printed items – looks like they’re going to have to wait!”
Production begins
Andy called Tom Dwyer, Solinear’s Director, to confirm that regular production could be scaled down in favour of manufacturing parts for face shields. Tom immediately agreed.
He commented “Solinear celebrated its 15th birthday last year and has gone from strength to strength. In the past two years I have witnessed a monumental surge in enquiries and as a result we have employed more staff, stepped up manufacturing and, as we had outgrown our previous premises, we moved to a much larger unit in November 2019.”
Tom continues “Solinear has successfully traversed the peaks and troughs of the construction industry and the devastating chasm of recession but a global pandemic is a complete unknown for our industry – many are in limbo. I speak for the entire Solinear team when I say our sympathy goes out to everyone affected by it. We will do all we can to assist in the effort to stop the virus spreading further so putting into practice Elliot’s brilliant idea and Andy’s considerable understanding of 3D printing we will scale down regular manufacturing and begin production of components for face shields immediately.”
Andy promptly contacted David Young, the Director of interACT & Connect LTD – a York-based enterprise, raising funds to help pay for materials to create face shields supporting frontline workers in the fight against Covid-19. Their priority is to have a network of people/companies with the right skills and equipment to make, print and assemble visors free of charge.
Andy received diagrams, instructions and the 3D model – supplied as an STL file – a format native to the stereolithography CAD software created by 3D Systems. The construct of this face shield is a popular Spanish design by Hanoch Hemmerich, currently being distributed across popular 3D printing sites and produced by numerous people around the world. The clamps have been printed using easy-to-print 100% recycled PETG plastic with the assembly of the visor and elastic strap fitted by others.
The future of Solinear
Solinear’s 3D printers will be dedicated to fabricating clamps for face shields for as long as required. Although capacity has been reduced, as the business adheres to strict government directives, manufacturing of Solinear’s architectural louvres and brise soleil continues. When lockdown is lifted installers will be deployed to sites to fit systems.
Tom concludes “Solinear would like to reassure clients that orders will be fulfilled, however, patience and understanding would be appreciated in this unprecedented situation. We are monitoring the COVID-19 situation daily and acting accordingly – the safety of staff, clients and the general public are of paramount importance at this moment in time.”.
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Useful links:
Free 3D printed visors for Frontline workers in York area
www.facebook.com/groups/231645954700635/
www.solinear.co.uk/
www.solinear.co.uk/blog/
www.solinear.co.uk/solinear-at-smart-factory-expo/
www.solinear.co.uk/our-3d-printer-will-be-helping-us-with-our-manufacturing-processes-in-the-meantime-fairytale-castle/
www.solinear.co.uk/product-range/
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Useful contacts:
David Young, Director of interACT & Connect LTD
Mob:07702 810817
Coordinating 3D printing, laser cutting, materials supply and distribution
David Young / Joyce at interactandconnect@gmail.com
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