Lockdown can be a frustrating time, but one Thales employee has created a cottage industry producing PPE on his home 3D printer to protect key workers in hospitals, care homes and shops from COVID-19 infection.

Ric Clark is a bids and projects manager in Cheadle Heath. Qualified in electronics, he also has a passion for motorbikes and mechanics, making and repairing equipment in his workshop at home.

An advanced rider, Ric volunteers as a blood biker, transporting blood and test samples to hospitals. He recalled a hospital visit shortly before lockdown: “There was a big increase in demand, and despite their morale and attitude, the staff looked tired and stressed; I heard them talk about trying to get face shields.

“I wondered what more I could do so I found designs online for single-use face shields you could make at home. Because of my interest in gadgets, I had a 3D printer on my desk, so I wondered if I could help.”

Ric downloaded a pattern and contacted organisations around Stockport which were appealing on social media for PPE. Printing a face shield frame takes around 90 minutes so Ric set up a production line using his 3D printer. His family helps, assembling 10 to 12 face shields a day and delivering batches to local schools, hospitals and care homes.

Ric has been providing the materials needed but local groups have helped out at times by giving him acetate sheets for the mask; the Women’s Institute even provided a bag of elastic for fastening straps.

The response from key workers has been warm: “The nursing staff at our local hospital has taken over 80 face shields so far and they’ve said they’re absolutely made up by what we’re doing. You could say we’re getting lots of repeat customers.”

Ric continues manufacturing face shields while there’s a demand. He received a small amount of crowdfunding from close friends which helped offset some of the early costs and Thales has provided 200 acetate sheets.

He is now enlisting support from other colleagues with printers, including Andy Grimshaw who Ric supplies with materials.

“Andy has even re-worked the design files to provide a better solution - a real Thales cooperative,” said Ric.

He urges others to visit the website printforvictory.org to see how they can help: “It’s a really satisfying feeling when you’re delivering something that’s helping someone down the line.”

You can find out more about how Thales employees are mobilised in the fight against COVID-19 here.