Down on the print farm: Pro-Mold VP uses 3D printed parts to make face shields

NORTH RIDGEVILLE — An almost musical whirring filled Ed Neugebauer's home Thursday, a symphony created by an orchestra of 3D printers. The machines whirred away, laying down layers of plastic that would become headbands for face shields. Neugebauer and his 8-year-old daughter, Amelia, clipped transparency sheets to the bands, creating a covering that hangs down past the chin. The goal is to give a measure of safety to "second-line" workers at essential businesses. "Obviously you wouldn't have these for doctors in an intensive care unit," said Neugebauer. "There are people out there in other places that can use them, like nursing homes and police officers. ... This is the new world we live in, and people need this level of protection." Neugebauer is vice president of Pro-Mold, a plastic molding plant in Kipton that creates trading card and memorabilia cases. The family-owned plant has been shut down under Ohio Gov. Mike DeWine's COVID-19 orders. Workers have been laid off, and the huge 20,000- to 30,000-pound molding machines are idled. So Neugebauer decided to put his knowledge to work at home. His 3D print farm can make 150 to 200 plastic headbands in a 10-hour day. A part that takes 20 minutes to print at home would take just 10 to 15 seconds to make at Pro-Mold in Kipton, he said. "The problem is the mold to make this would take a few weeks, and obviously we don't have a few weeks," he said. "So we're kind of improvising, doing what we can with what we have." So far, Neugebauer has made face shields for Northcoast Endodontic Specialists, Hofmann Plumbing, Northridge Health Center and Lake Ridge Academy, where Amelia is a student. Most recently, Hospice of the Western Reserve took 300 of the printed units, he said. Using shop towels, Neugebauer also created protective masks for the Cleveland Police Department. They look much like N95 masks but are slightly less effective. Neugebauer said he believes they filter 92 percent of particles as small as 0.3 microns. By comparison, the coronavirus is about 0.125 microns in size. Contact Jason Hawk at (440) 329-7122 or news@lcnewspapers.com.