Face mask extenders
Face mask extenders
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This fast paced project to manufacture a mould tool to make face mask extenders for NHS workers at the beginning of the pandemic was a culmination of the experience I had gained during my time at Capricorn Mouldings.
This fast paced project to manufacture a mould tool to make face mask extenders for NHS workers at the beginning of the pandemic was a culmination of the experience I had gained during my time at Capricorn Mouldings.
This project was born from a member of staff whose wife was working in a hospital at the beginning of the Covid-19 pandemic and informed us that people were using improvised hooks to stop mask loops rubbing on their ears. From this I was keen to manufacture a mould so that we could produce these on mass and donate them to NHS departments all over the country.
This project was born from a member of staff whose wife was working in a hospital at the beginning of the Covid-19 pandemic and informed us that people were using improvised hooks to stop mask loops rubbing on their ears. From this I was keen to manufacture a mould so that we could produce these on mass and donate them to NHS departments all over the country.
In just 5 days, I designed and manufactured a mould and automated the production of this product so we could rapidly supply them!
Below is some pictures of the manufacturing process:
CNC milling of cavities
Finished cavity block ready for EDM
CNC milling of graphite EDM electrode
Finished Electrode
Notches milled into elctrode to create living hinge
EDM of cavities
EDM of gates
Finished tab gate
IMG_6912.movProduction video
Production video
This video shows the face mask extender once in production. The parts are being injection moulded in a food grade polypropylene with a cycle time of 10 seconds. The sprue picker removes the scrap runner system to be reground and fed back into the process before the parts are ejected from the mould.
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