They're donating a million face shields by the end of the week to hospitals and medical facilities with the greatest need, and 20m by the end of the month, designed by Apple and sourced via their existing supply chain.
Did they adapt an existing cutting tool? New tool? What were those factories making before the pandemic?
The entire shield is a clear plastic film. It’s held against the forehead using a fabric strap. The shield appears to be either die cut or laser cut, which explains the production speed. A lot of the face shields shown online are 3D printed with hard plastic components, which is a very slow process.
The material looks a lot like the clear plastic film that wraps an iPhone or even an iPad charger. The shield folds together in the same origami-like way. Based on comments about the supply chain being involved, it seems like they leveraged the existing manufacturing process for Apple product packaging and thickened the plastic.
The design is very smart from a manufacturability point of view, I expect we will see other factories making similar face shields in the 100s of millions shortly. Which is great... One of our local supermarkets is already using similar face shields for their customer-facing staff.