The face shield distribution seems to be caught up in my area, so I decided to look into an emerging need from healthcare workers: ear savers.
I started out by using this well-known Thingiverse design. Most people 3D print this one, but I still have PETG sheet to spare which will work just as well on the lasercutter.
I quickly noticed that – though it is functionally perfect – this design is not material efficient (48pc/sheet). I stumbled upon a Glowforge design that features very little cutting waste, so I experimented with that as well. The original was a little short in my opinion, so I made it a little bit longer. I got 70 pieces out of the same work area with this design.
Still not satisfied, I remixed the Glowforge design even more, before settling on the final piece, seen in the middle of the picture below.
From top to bottom: extended Glowforge design – mine – Thingiverse design
As you can see it has the longest reach (both ways) out of the bunch. I made it go wider the nearer you get to the ears, for maximum friction relief.
I can cut 60 pieces out of one sheet, which I found to be an acceptible tradeoff.