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NEWSLETTER
MAY 2020
MAKERS ARE PITCHING IN TO STOP THE SPREAD OF COVID-19 read all about PPE Face Mask Challenge | CPAP Adapters Reinventing the N95 Respirator Mask | PPE Intubation Tent and more
WWW.NOVA-LABS.ORG
BOARD OF DIRECTORS Sam Aparicio -
President Email: sam.aparicio@nova-labs.org Slack: @sam
Chats Fri. 7pm
Secretary Email: karen.shumway@nova-labs.org Slack: @karen shumway
Karen Shumway
Shane Smith
Daryl Peace
Mona Davis
Jeff Spugnardi
Jim Girardi
Marybeth Haneline
Margaret Kositch
Brian Jacoby
Vice President of Outreach Email: daryl.peace@nova-labs.org Slack: @dp Vice President of Operations Email: jim.giraldi@nova-labs.org Slack: @jim Treasurer Email: margaret.kositch@nova-labs.org Slack: @margaretk
STEWARDS
Assistant Treasurer and Director Email: mona.davis@nova-labs.org Slack: @mona
Director Email: shane.smith@nova-labs.org Slack: @shane4now Director Email: jeff.spugnardi@nova-labs.org Slack: @jeffspugnardi
Director Email: marybeth.haneline@nova-labs.org Slack: @marybeth Director Email: brian.jacoby@nova-labs.org Slack: @bjacoby
Doug Calvert
Patrick Marstall
Steve Fritzinger
Aaron Goldstein
Patrick Thompson
Paul Chase
Frank Hum
Carrie Hafer
Woodshop Steward Email: doug.calvert@nova-labs.org Slack: @dfc CNC Steward Email: aaron.goldstein@nova-labs.org Slack: @aaron Metalshop Steward Email: frank.hum@nova-labs.org Slack: @fhum
TEAM LEADS
Blacksmith Steward Email: patrick.marstall@nova-labs.org Slack: @patmarstall Laser Lab Steward Email: patrick.thompson@nova-labs.org Slack: @patrickt
Patrick Thompson
Jeanne Marshall
Fred Briggs
Fabiana Cesa
Daniel Schneider
Outreach Team Lead Email: jeanne.marshall@nova-labs.org Slack: @jeanne.marshall Youth Team Lead Email: fabiana.cesa@nova-labs.org Slack: @fabiana
COORDINATORS
Safety Team Lead Email: patrick.thompson@nova-labs.org Slack: @patrickt Entrepreneur Team Lead Email: fred.briggs@nova-labs.org Slack: @fred briggs Volunteer Team Lead Email: daniel.schneider@nova-labs.org Slack: @daniel schneider
Farina Zeb
Bob Coggeshall
Tara Tavia
Michael Douglas
Education Services Coordinator Email: farina.zeb@nova-labs.org Slack: @fari Event Services Coordinator Email: tara.tavia@nova-labs.org Slack: @tara Page 2 | May Newsletter | Nova Labs
3D Printer Steward Email: paul.chase@nova-labs.org Slack: @paul chase
Crafters Cove Steward Email: carrie.hafer@nova-labs.org Slack: @carrie
Jennyfer Peterson
Operations Services Email: jennyfer.peterson@nova-labs.org Slack: @jennyfer
Plastics and Composites Steward Email: steve.fritzinger@nova-labs.org Slack: @steve fritzinger
Software Development Coordinator Email: bob.coggeshall@nova-labs.org Slack: @bobcoggeshall Network Services Coordinator Email: michael.douglas@nova-labs.org Slack: @mdouglas
Nick Latanze
Facilities Team Lead Email: nick.latanze@nova-labs.org Slack: @nick
CONTENTS 04
Letter from the Editor
05
Fundraising Update
06
We Searched All Through the Land, but no PETG Could be Found
07
CPAP Adapters: Design to Delivery in Three Days
08
PPE Face Mask Challenge: A 1000% Communal Effort
10
Nimble, Distributed Production and Delivery, aka, Team PPE Transport
12
Reinventing the N95 Respirator Mask
14
Want to Join our PPE Efforts?
16 The Airway Procedure Tent Background: from a Frontline Clinician 18
Nova Labs PPE Intubation Tent
20
Event Sportlight
22
Blacksmithing at Home
24
Show Us What You Got
26
The Future of Inefficient Transportation
28
Happening in May
Nova Labs | May Newsletter | Page 3
LETTER FROM THE EDITOR
As Secretary for Nova Labs, I am entrusted with writing the agenda for our monthly board meetings. I usually start by duplicating the previous month’s agenda and polishing its minutes, which also serves to remind me of any open business that hasn’t been addressed in recent weekly Benchwork meetings. The most recent agenda was particularly trying because the March board meeting happened as everything was beginning to shut down, but hadn’t quite yet in Northern Virginia. Our world is so very different now than it was just a short month ago, and reading those minutes highlighted just how quickly those changes happened. What I didn’t know in early March, though, was how quickly Nova Labs members would respond to the pleas of “Get us PPE!” from healthcare professionals and frontline workers. When Margie Foster first asked Jennyfer Peterson to create a PPE_Challenge channel on Slack to give these volunteers a space to coordinate and collaborate from home in the midst of Nova Labs’ physical shutdown, I don’t think any of us imagined that today we would have twelve Slack channels addressing different PPE teams, or that Jennyfer would be adding fifteen new individuals to those channels every day. The worst part of this pandemic appears to be sitting at home, feeling useless. The PPE teams all have a purpose, the knowledge they are providing critical equipment to help save lives, and the camaraderie of self-organized, autonomous teams. This is the maker movement at its best. It is agile, nimble, and able to quickly prototype, produce, and deliver innovative solutions to real-world problems.
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In addition to the PPE challenges, the instructors of Nova Labs have been working closely with Farina Zeb and Jennyfer Peterson to pivot to online classes and events. In just a few weeks, they have created a diverse selection of instructional and demonstration events. Some are free to attend, others are low cost. All have been well done. With the physical makerspace closed, members appear to be exploring new crafts by attending these classes. The “Show Us What You’ve Got” Slack channel provides strong evidence that Makers Gotta Make, and members are still making at home and sharing their creations online. It’s been really enjoyable seeing new faces in the now-virtual Fireside Chat with president Sam Aparicio each week. In short, I have little doubt Nova Labs will not only survive this crisis, but will come out of it stronger than before. Yours in Making, Karen Shumway Secretary, Board of Directors
Find me on Nova Labs Slack: @Karen Shumway
Fundraising Updates by Daryl Peace PPE Challenge Supplies and equipment needed to safeguard medical staff, diagnose and treat the sick, and help prevent the spread of COVID-19 were and still are in critically short supply. These supplies include hand sanitizers, nasal swabs, face shields, N95 respirator masks, and disposable ventilator valves. Manufacturers across the country are increasing their output to meet this demand and non-traditional suppliers such as distillers have switched some of their production from whiskey and gin to hand sanitizer, yet there is still a demand from the medical community. The PPE challenge was born, whereby small-scale, low-volume, highflexibility manufacturers and makers across the country are coming together to help fill this gap. Designs were developed and shared across maker communities, partnerships forged with 3D printing firms, donations provided for raw materials procurement, production processes were started, and distribution coordinated. At Nova Labs, there are five active production activities: • Cloth mask production • Face shield production • N95 respirator production • Intubation tent production • CPAP adaptor production Nova Labs is proud of its membership’s mobilization to assist the medical community to forward its mission by manufacturing PPE. In addition, Nova Labs is providing material support for raw material acquisition to empower our makers via the PPE challenge fund. To date, members’ efforts have supported hospitals and medical centers throughout the D.C. area and as far away as Brooklyn, New York; Detroit, Michigan; and even Wonju, South Korea.
As of May 4, the total PPE donation was $25,477 in cash and $1,000 in-kind donations (3D printer filament from Micro Center). If you would like to donate to the cause, please visit the website. If you want to participate in the challenge, please reach out to Margie Foster. Adopt-a-Member Initiative Nova Labs recognizes the financial impact and hardship COVID-19 has inflicted on several members within our community. To help those in need, we have started the Adopt-a-Member initiative, whereby members can provide financial assistance to those in need. The initiative has just started and already we have a $25/month donation and a $100 one-time donation. Let’s help our fellow members and donate here. Grants Pursuit The Nova Labs board is pursuing funds via the Emergency Economic Injury Disaster Grants provision of the CARES Act, which provides a $10,000 grant. In addition, on April 7, the Nova Labs board applied for a $30,000 grant from the Greater Washington Community Foundation through its COVID-19 Emergency Response Fund. PPE Challenge Fund Link
Nova Labs | May Newsletter | Page 5
We Searched All Through the Land, but no PETG Could be Found by Aaron Goldstein The DMV maker community began building and donating face shields because traditional industry was not building them fast enough to meet the needs of the medical community. A couple of weeks ago, just one single hospital in Maryland needed 2,000 and could not find a supplier. We thought that traditional industry would quickly come online, build enough shields, and we would move on to other PPE projects. Unfortunately, we were only partially correct. It turns out that traditional industry is still not making enough shields, but they did ramp up and buy all the transparent plastic we were using (.020” and .030” PETG). We called every shop within 100+ miles of Nova Labs and several online companies, but none had any in stock. A few of them wrote down our names to call us back when the sheets came in from China; they guessed it would be late April or May. A few weeks later we got an interesting call. Polymershapes in Jessup, Maryland had sheets
Page 6 | May Newsletter | Nova Labs
with opaque streaks and distortion due to a manufacturing error; did we want them? They gave us four sheets to test and we were able to use a good percentage of each. Moreover, we have the human power to check each shield and discard the ones with defects. A couple of conversations later, they were willing to gift us 154 sheets. Even if we change the design and some of the plastic goes to waste, that is still thousands of shields! When we went to collect the plastic, I said they could leave the pallet in the parking lot and we would do the rest; we’re not paying, so they should focus on their customers. Instead, their manager pulled out the forklift and helped us fold each piece into our vehicles. On the way back to LaserThing.com to deliver the sheets, we donated 100 shields we made from the four test sheets to Holy Cross Hospital in Silver Spring. Click here to see more face shields images
Find me on Nova Labs Slack: @Aaron
CPAP Adapters: Design to Delivery in Three Days by Paul Chase
On Friday, April 10th, Nova Labs was approached with a new PPE Challenge: the D.C. Fire and EMS reached out because they were unable to source adapters for their CPAP equipment, which are needed to add inline filters to the equipment. The adapters are a simple part – so while we needed a design, it only took a few minutes to prototype and print; the first successful part was completed the day Nova Labs got the call. At 8:38pm that Friday evening, the final file was posted to Slack and we asked the Nova Labs community to step in and make 1,000 parts which were 3D printed within three days! The first delivery of 100 went out Monday morning, with the remainder being ferried across town by an additional group of dedicated volunteers. The PPE Challenge previously organized to set up drop points and transportation for the Prusa face shields, fabric face fasks, N95 masks, and earsaver straps stepped up once again to collect and deliver the parts and help keep our first responders safe.
Find me on Nova Labs Slack: @Paul Chase
Nova Labs | May Newsletter | Page 7
PPE Face Mask Challenge: A 1000% Communal Effort by Anne Savage
Page 8 | May Newsletter | Nova Labs
What involves breaking needles, burning your fingers, cutting yourself with a sharp implement, steaming up your glasses, wrestling with yards and yards of tangled fabric, and, of course, prototyping model after model before coming up with a workable option? Why, making fabric face masks for medical institutions, of course! In an occasionally painful but definitely satisfying effort to meet the Nova Labs PPE Challenge, makers of all experience levels are breaking out sewing machines, cutting tools, and irons to make fabric face masks. Nova Labs has accepted requests for 340 masks so far, from institutions that include Chambersburg Hospital, Healthworks (Reston, Sterling, and Leesburg), and Virginia Cancer Specialists. Our handmade masks will generally be used to cover and extend the life of existing PPE masks at these facilities. Our capacity is limited to frontline healthcare workers for now, due to the amount of time it takes to produce a sturdily-made mask that will withstand dozens of trips through institutional laundries. We’ve received many requests that we’ve had to say “no” to, but last week in April we crossed the “500 face masks completed” line – yay! – and we’re always looking for new volunteers with access to sewing machines. With the skilled leadership of Jalene and the organizational know-how of Jeanne Marshall and Sally Byers, our friendly community of makers at #ppe_fabricfacemask on Slack has figured out how to meet the challenge. In addition to sewing, we are using laser cutters to create acrylic templates and precut dozens of fabric mask pieces for kits—shout out to Fabiana Cesa and Dave Moretti! We’re using 3D printers to create bias tape folders and mask pleaters—thanks to Paul Chase, Scott Shumway, Shane Smith, and Patrick Waters! We have folks soliciting donations of fabric, tape, and wire, communicating with medical organizations, reaching out to find additional sewists, ferrying supplies around Northern Virginia, arranging for contactless pickups and drop-offs, and so much more.
Although some medical organizations request that a specific mask pattern be followed, not all do, so we spent a week researching patterns and testing them out, leaning towards patterns repeatedly requested by medical organizations. After researching fabric choices (a daunting task as new information emerges every day), we’re now using tightly woven 100% cotton fabric. We send a special thank you to Sally Byers, UpCycle Creative Reuse Center, and Reston community donor Karen Hawley for significant donations of the fabric we need. Every single volunteer is important. As Jalene says, “this [is] a 1,000% communal effort. Every bit of technical sewing problem solving, every piece of fabric acquired and delivered, every logistical issue, was solved using the wisdom and effort of our little crowd.” In addition to the folks mentioned above, we send thanks to Amanda, Amy, Crystal, Dana, Jennifer, Joo Lee, Karen James, Karen Shumway and family, Katelyn, Margie, Melanie, Mike, Mona, Siobhan, Thuy, Yvette, and all of you who are a part of this effort. Now, about those injuries I mentioned above: I suspect I’m not the only one who’s had some of these mishaps. Yards of fabric can get tangled as we pre-wash and dry them on “hot.” It’s easy to nick yourself when you are using a rotary cutter to cut dozens of mask pieces and strips. When making bias tape, it’s not uncommon to burn your fingers a bit as you fold that thin strip in half to iron it. Reading glasses can steam up when you wear them to see the folds you’re ironing! Lastly, sewing machine needles break when you are attaching the nose-shaping wires with a zigzag stitch, and you accidentally sew on the wire; I did this at least three times. But… none of these small mishaps matter once you have stitched the bias tape closed, given everything a final press, and – TA DAH – you have a completed mask that will help protect a frontline medical worker! Click here to see more images Find me on Nova Labs Slack: @Anne_Savage Nova Labs | May Newsletter | Page 9
Nimble, Distributed Production and Delivery, aka, Team PPE Transport by Thant Aung together for the PPE Challenge. In under four weeks, our team of part-makers grew seven-fold, we took on five times the number of projects, and we’re still growing. How do we move all these parts and supplies around when we’re not allowed to get together in a single location? In the first week, I was transporting the face shield parts from the makers to the assemblers. The tracking sheet was small enough that I didn’t have to scroll through it. Peter von Elling, Margie Foster, and I were tracking individual transports to meet the requests. The destinations were only for two primary assemblers. It was simple. As the PPE effort was taking off, more and more part makers came on board and there were individuals without 3D printers who wanted to contribute. The administrative burden was growing and it no longer made sense for us to track every single transport. It was late March when I saw a Facebook post about Nova Labs’ PPE Challenge. Earlier that week, I had been reading news of medical staff not having enough PPE, so I thought it amazing that Nova Labs would be making a direct impact. I figured I’d help by making a PayPal donation as I didn’t have a 3D printer, and by the time I’d be able to get one and have it adjusted, Apple and other companies might already be making local deliveries of the much-needed PPE. I started to wonder if I could help in some other way in the meantime? I had been working from home for a week at this point, and my family had been watching the news all day worrying about what would happen. My phone’s newsfeed was full of COVID-19 posts. I wished there was something I could do rather than staying home so I sent a message asking if I could help. I’ve learned this is a common story of how all of us have come Page 10 | May Newsletter | Nova Labs
We needed to scale up our transport system and have a more structured process in place. With a new volunteer, Tiffany Winsor, Peter, Margie, and I moved to the next logical step of having drop off hubs. Luckily, more volunteers were offering to drive at the same time. Tiffany compiled a list of folks who were willing to share their locations as hubs and I started putting all the addresses on Google Maps to see where everyone was and our current transport model was born. I didn’t have any prior experience with distribution, but fortunately I recently read Marc Randolph’s “That Will Never Work,” Netflix’s early story of their DVD-by-mail business, and I borrowed some ideas. I cannot deny that my younger days of playing a ton of Starcraft might also be contributing to move armies and to gather resources around a map. Our initial number of part makers started at ten and has grown to about eighty today. There are
now ten drivers instead of two. We’ve expanded to make CPAP adapters, mask straps, Mala masks, fabric masks, intubation tent brackets on top of the face shields in less than four weeks. The final destinations now change from project to project. It is getting complex, but our tracking sheets play an enormous role in organizing these efforts. We moved from makers individually communicating via Slack when the parts were ready to them updating the tracking sheets on their own. We progressed from having to pick up at individual locations to makers dropping off parts at their closest hubs 10-15 minutes away from them. The hubs also offer bins outside for a safe, nocontact drop off and pick up. The drivers closest to the hubs are assigned to transport parts from hub to hub. On some occasions, the drivers will pick up from individual locations if the makers are unable to drive and if the parts need to move urgently. We would need an army of drivers if the part makers were not willing to drop parts off at the hubs. This transport system isn’t possible without the makers constantly updating the tracking sheets and delivering parts. Kudos to them! If you have a chance to look at the map of the hubs, you will find Pho Bytes in Fairfax is one of the hubs. It’s an amazing location because I’ve gotten into a habit of getting Pho with meatballs
when I’m picking up parts at Pho Bytes. Not to mention they are giving 20% off if you mention Nova Labs, and they have great quality food. The owners, Nhan Nguyen and his brother-in-law, are printing 3D parts, and Nhah’s wife, Thuy Nguyen, is sewing fabric masks. They are also donating food from Pho Bytes to hospitals to lift up the spirits of our nurses and doctors on the front lines. You can donate on GoFundMe if you want to contribute to their ongoing efforts. I’m thankful to Pho Bytes and everyone else who has come together to organize and volunteer in this PPE Challenge. I’ve gotten myself a 3D printer and started contributing. I have been able to network with almost all the makers around the DMV and I have gotten help with 3D printing. There’s no ego here. People are willing to jump in to do anything that’s required and make things happen. There’s nothing like a shared purpose of meaning to help us get through these trying times. If I may borrow Margie’s words, you should pat yourselves on the back if you’re organizing, volunteering, or contributing to this PPE effort in any way. You are awesome!
Nova Labs | May Newsletter | Page 11
Reinventing the N95 Respirator Mask by Joshua “MalaMaker” Malavolti, Member of River City Labs, Makerspace in Central Illinois On May 20, the N95 alternative mask project, which ended up being called the MalaMask Project, began in a garage in Central Illinois. After about a week-and-a-half of research and posting on social media, I was followed on Twitter by an account named @AlecRandazzo, who at the time followed one person and was followed by one person. I came to learn through interactions with Alec that he was... a) Not a bot out to seek my bitcoins; b) Alec Randazzo in real life; and c) a member of Nova Labs.
to 3D print the plastic components of the Malamask, mold and cast the silicone gaskets, cut the approved filter materials, create straps, and assemble the masks for distribution to local healthcare professionals. For more detailed information on Malamasks and their specs click here
From there, Alec plugged me in to Nova Labs and they became an integral part of the MalaMask project. Nova Labs helped to shape the playbook and documentation as it is published today. Without the help of their makers and the resources they offered, the project would not be where it is today, which truly shows the power of the maker community. Thank you Nova Labs, from myself and on behalf the members of River City Labs in Peoria, IL. Currently, Nova Labs volunteers are working
“A mask is only as good as the filter that it uses... Filter First, mask second!” Page 12 | May Newsletter | Nova Labs
THANK YOU for being part of the PPE CHALLENGE
PPE Challenge
Click here for more information
Nova Labs | May Newsletter | Page 13
Want to Join our PPE Efforts? by Margie Foster The Nova Labs community has joined forces with other local organizations and people from all over the DMV area to manufacture and donate medical PPE (Personal Protective Equipment) to hospitals and others in need. If you would like to join us, read on. We welcome help in a variety of forms, from drivers, to sewists, coordinators, 3D printer operators, assemblers, and more! What are we making? Each project has its own Slack channel. If you came in for one project and you want to learn more about another, just reach out and ask for access to the other channels. We’ve got some really great projects! Always check the channel descriptions, FAQ and pinned posts to get an idea of what’s going on.
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Airway Procedure Tent (APT) #ppe_airway_procedure_tent Makers are working with medical professionals to create and test a device that protects doctors from aerosolized virus. Fabric Masks | #ppe_fabric_masks Sewists are working together from afar to laser cut fabric into kits and sew as fast as they can. If you or anyone you know is interested in firing up the sewing machine, we can use the help! Reusable Face Shields | #ppe_face_shields Using all the 3D printers we can find (and if you can find more, please send them our way) our team is cranking out frames for reusable face shields. Shield plastic is cut on laser cutters.
Ear-saving Headbands #ppe_headband_w_buttons Saving the ears of the medical professionals by sewing headbands with buttons attached to hold the mask elastic off of their ears. Ear Savers | #ppe_ear_savers Much like the headbands, these little ear savers hold the elastic so ears don’t have to. Mask straps have been 3D printed and may soon transition over to being laser cut. Reusable Respirators | #ppe_n95 Reusable face masks are made with 3D printers and casting silicone, and can either stretch one N95 mask into 6 filters, or hold a DIY filter that’s been rated at an N95 level. Specialized Adapters | #ppe_ventilator_adapters Sometimes we get requests for specific adapters. Our crew models a solution, 3D prints, tests and takes to production to fill orders of the first responders and medical professionals in need. How can I help without a 3D printer or sewing machine? There’s room for everyone here in the PPE mission! Not only can you join channels and cheer the makers, but you can also help with organizing, transportation, and assembly! So much goes into making this production work. We could also use help with fundraising, especially identifying opportunities with corporate sponsors, and general outreach to local government and media. Assembly and production tasks: #ppe_production_assembly Drivers and transport coordinators are always needed: #ppe_transport I have a 3D Printer. Now what? Make sure you’re in the #ppe_3Dprint_central_ command channel! Add your info to the spreadsheet. You may need to ask to be added to additional channels along the way.
Are we selling what we make? Nope! Everything we make is donated to people on the frontlines in the fight against COVID-19. Who are the recipients of the PPE? Most of our donations have gone to local hospitals, hospice providers and first responders in the DMV area, but we have also sent some PPE to some of the most affected hospitals in New York, all the way down to North Carolina. Do you accept donations? Absolutely! We accept monetary donations as well as materials. Financial donations can be made here: www.nova-labs.org/PPE-challenge/. Please share this widely, and if you have any connections to corporate sponsors, we would love to meet them! Materials are accepted as the projects need them. Please bring it up within the relevant project channel, and someone will be able to tell you what’s needed.
How do I get started?
1 Click on image above or download app
2
All volunteers, please express your interest by sending us an email to membership@nova-labs.org and we will add you to the proper channel
3
Once in the channel, introduce yourself to the group and see how you can get involved.
4
Each channel maintains its own spreadsheet that can be found in the channel details.
5
To participate as a volunteer add your name to the spreadsheet.
6
The community will be happy to answer any questions. Nova Labs | May Newsletter | Page 15
THE AIRWAY PROCEDURE TENT BACKGROUND: from a Frontline Clinician
by Amy Keim, MS, PA-C | Associate Clinical Professor of Emergency Medicine | George Washington University School of Medicine and Health Sciences | George Washington University Medical Faculty Associates
When COVID-19, otherwise known as SARSCOV-2, struck the US, it was met with decades of emergency preparedness. The severe acute respiratory syndrome (SARS-COV-1) epidemic, as well as the Middle East respiratory syndrome (MERS-COV) had highlighted the challenges of managing a modern outbreak of a novel virus that easily crossed international boundaries and resulted in acute respiratory distress with high fatality rates. Despite what we learned, the enormous amount of research, advances in medical care, expertise that grew out of those experiences, and development of robust emergency management practices, SARS-COV-2 has presented new and unanticipated challenges that have blindsided our healthcare system. We are rapidly identifying new problems and innovating to overcome them. This includes innovating to stop the spread of the virus. COVID-19 virus particles are spread through the respiratory tract by aerosolization. Page 16 | May Newsletter | Nova Labs
This aerosolization of the virus can occur when someone with the viral infection coughs, talks, or breaths. A nearby individual can contract the virus through their mouth, nose, or eyes. In the hospital setting, patients with novel airborne respiratory viruses like COVID-19 are managed using Airborne Precautions. This is a set of very specific precautions taken by the healthcare team to limit the spread of the virus to other patients and staff. It includes placing a patient in a negative pressure room (air pulls from the room into a special filter system) and wearing a high level of personal protective equipment (PPE), including an N95 mask. When a patient with suspected or confirmed COVID-19 is in severe respiratory distress or cardiopulmonary arrest, life-saving interventions are rapidly deployed by the healthcare team. These interventions include procedures such as CPR or endotracheal intubation, which significantly
increase aerosolization of infectious particles and put the healthcare team, and potentially other patients, at higher risk of contracting the virus. As such, healthcare workers take extensive precautions to limit aerosolization while balancing the emergent needs of the patient. Because patients can be infected with COVID-19 without symptoms, or their presenting condition may be an atypical presentation of COVID-19 (like a life-threatening heart rhythm cause by the virus’ effect on the heart), any patient requiring a procedure with increased aerosolization requires the same level of precautions. The sudden influx of patients requiring this level of airborne precaution has overwhelmed hospitals. Negative pressure rooms are very limited as are the higher levels of PPE recommended with the increased level of exposure risk. Many hospitals started implementing readily available plastic drapes over the patients to try to decrease aerosolized particles during airway procedures. However, the drapes create significant challenges by interfering with visibility and the mechanics of the procedures themselves, while providing an unreliable barrier.
Clinicians who have contributed to this project through tent testing and design feedback include: Claudia Ranniger, MD Assistant Professor of Emergency Medicine Director of Simulation George Washington University School of Medicine and Health Sciences George Washington University Medical Faculty Associates Michelle Divito, MD Department of Emergency Medicine Walter Reed National Military Medical Center David Yamane, MD Assistant Professor of Emergency Medicine Assistant Professor of Anesthesiology and Critical Care Medicine Chief, Critical Care Section George Washington University Medical Faculty Associates
To better prepare for the inevitable influx of respiratory distress patients with suspected or confirmed COVID-19, medical and nursing staff practice new protective protocols using simulated patient exercises. It was while participating in one of these training events, watching those plastic drapes, that reality hit hard. How do we balance our safety with that of our patients? There has to be a better way. The following day I contacted Nova Labs, who were already providing local hospitals with highquality 3D printed face shields. I had an idea, but I needed a skilled engineer and manufacturers. The idea was to design and produce a tent to decrease the spread of aerosolized particles, give the medical provider full visibility and range of movement, accommodate different types of airway approaches, and not interfere with chest compressions/defibrillation. It would have to be inexpensive to make, easily produced by volunteers, cleanable with available hospital disinfectants, and pack flat for distribution.
James Phillips, MD Assistant Professor or Emergency Medicine Chief, Disaster and Operational Medicine Section George Washington University Medical Faculty Associates Joshua Kessler, MD Department of Emergency Medicine Walter Reed National Military Medical Center Shannon Stout, MD Department of Emergency Medicine Walter Reed National Military Medical Center
Nova Labs | May Newsletter | Page 17
NOVA LABS PPE INTUBATION TENT by Bo Wernick
In early April 2020, the Nova Labs volunteer community, in cooperation with medical professionals, began developing a low cost foldable intubation tent. It was inspired by the popularity of large acrylic cases designed to prevent the spread of aerosolized particles from Covid-19 patients infecting medical professionals. The Nova Labs community was tasked with developing a lightweight and collapsible version that could meet the complex needs of the medical environment while reducing the storage footprint and high cost of the existing products.
Intubation with, and without, Personal Protective Equipment (PPE)
The process began with a requirement-gathering effort between Bo Wernick at Nova Labs and Amy Keim, PA-C, who was working as a medical professional in the Washington DC area. Those requirements led to a brainstorming session where a variety of challenges were identified with existing solutions. After some group brainstorming with a team of Nova Labs volunteers, a concept began to take shape, and a plan was put into motion.
Fit check tools used to identify size and shape requirements.
The development process began with several “fit check” prototypes. These tools were built to rapidly gather information about access port locations, size and shape optimizations, and niche features like sealing ports, enabling removal of the device while the patient was connected to machines, and attaching the tent firmly to the patient’s stretcher or gurney. The initial fit check tools were cardboard, hot glue, and plastic sheeting. The fit check tools were tested in the medical environment and new measurement feedback was provided. Page 18 | May Newsletter | Nova Labs
With the information from the fit check tools, the Nova Labs team was able to create a “form and function� prototype to better evaluate the final design approach. Some additional refinements were noted, such as adding velcro slits. These slits would allow the entire apparatus to be removed and replaced without disturbing tubes and wires that connected the patient to machines in the room through the various access ports.
The form and function prototype made from aluminum rods and 3D printed corner brackets. The overlay is made from heat-sealed vinyl with velcro access ports.
The final step was preparing for beta unit manufacturing. These first 50 units would be used to help medical professionals stay safe on the front lines of the Covid-19 pandemic while gaining valuable feedback on the product from real world end users. The Nova Labs team ran several manufacturing tests to determine the most cost- and time- efficient ways to seal the sheets of vinyl, cut and bend the aluminum rods, 3D-print the corner brackets, and make videos and instructions to allow our extended volunteer community to participate in the manufacturing effort. The NL community also developed a budget and designed a fundraising effort to fund the production of fifty units.
(Left) Engineering drawings for the substructure. (Center) 3D printed corner bracket print file. (Right) Completed 3D printed corner bracket.
The Intubation Tent is currently in beta testing with the first 50 units going to 3 hospitals. We recognize the need for this product and so we are planning for larger production runs with the support of vendors around the country, and eventually globally. Our goal is to be able to produce enough product for any organization who wants it at an affordable price. We plan to donate a portion of the proceeds back to Nova Labs to help them continue to support their amazing maker community. Click here to read more about Airway Procedure Tent Information Nova Labs | May Newsletter | Page 19
EVENT SPOTLIGHT by Jennyfer Peterson
Missing your makerspace? Too far away to join in the making? The makerspace may be closed, but you can still continue learning new maker skills. Continue learning from wherever you are. All classes and events are in our virtual classroom. Our classes still feature a live instructor/host, highly interactive learning, and a materials list is provided so you get supplies and learn by following along from the safety of your own home. Woodworking Classes Online Even when the makerspace is closed, makers gonna make. Our woodworking instruction crew is busy keeping you inspired and engaged during this downtime. Patrick Waters (Woodshop Cowboy) has moved his Project Class series online and moved it to Wednesday nights. On April 22nd, he walked through the design and construction of a simple kitchen cabinet. In this class, students learned to source and prep plywood the easy way, use all the necessary tools, joinery techniques, door construction and finishing to create your own kitchen cabinet at home or at a local makerspace. On May 6th, he will build a simple box with a raised panel lid. This box will feature miter and spline joints, raised panels and bullet hinges. Click here to register On May 22nd, he will demonstrate making basic dadoes and half-lap joinery on the table saw for a workbench. Click here to register STEM4Kids Virtual Meetings If you have precocious children, the youth team at Nova Labs has a new bimonthly Saturday afternoon get-together session where they teach all sorts of cool STEM skills. Pulling from a broad array of expertise and hosts, kids have learned graphic arts, computer programming, basic electronics, magic tricks, marble runs, and more. Sessions last a little over one hour, just the perfect amount of time to get yourself into and out of trouble. The best part - parents and older teens are always invited to help out. We are constantly on the lookout for interesting topics and new faces to be part of the planning. Please contact Fabiana Cesa, our Youth Team Lead (@Fabiana Cesa), if you are interested in joining the crew. Page 20 | May Newsletter | Nova Labs
Introducing the Nova Labs Institute of the Future (IoT-F) Does your student work best with a live teacher instead of a video? That’s what a lot of parents are learning. Give your Kindergarten to High School student a headstart on the future with classes that support careers in science, technology, and art. Nova Lab is a place where we focus on hands-on, projectcentric learning. Now your child can benefit from our mentorship-centric programs. Start with our program online now and prepare for our new classes at the makerspace when we open again. You can pay for the classes you need, or subscribe to our IoT-F monthly subscription and get unlimited classes for Free with a $50 a month subscription. Contact info@nova-labs.org for more information. Exciting classes are being added. Our first classes: Physics and Engineering for K-5: For students in grades Kindergarten through 5th grade. This class is designed to engage elementary students with basic, hands-on knowledge of topics in physics and engineering. Click here to register Help for Highschool: This class is intended to augment first year high school chemistry courses for students adrift in the rapid transition to online learning. Our experienced science teacher will meet LIVE with students twice a week (Tuesday and Thursdays 3-4pm) to address content questions and perform lab experiments using the Quality Science Tools Microchem Home Kit. Click here to register We’ll soon have math, blacksmithing, history, CAD, electronics and other classes
Nova Labs | May Newsletter | Page 21
Blacksmithing at Home by Pat Marstall
My wife and I were watching some videos on how to make some leather stuff, and she mentioned at one point that to really do justice to one design she would need a skiving tool. This raised all sorts of questions, the primary one being, “What the hell is a skiving tool?”; followed closely by, “What the hell is ‘skiving’?” Well, as luck would have it, one of my favorite YouTubers (the wonderfully-named Torbjörn Åhman) recently made a video on how to make a half-moon leather knife, and it turns out that the steps could be largely replicated by an amateur like me using stuff I have lying around at home. The blade is made from an old 10” chop-saw blade that I had collecting dust in the corner. Chances are that I will find a reason to need the blade now that I’ve ruined it, but that’s the chance you take. I had three abrasive cutting wheels for my angle-grinder, and it turns out that I needed all three of them to cut out the shape from the high-carbon saw blade. But I just made it and didn’t need to break curfew for an unnecessary trip to Lowes.
Page 22 | May Newsletter | Nova Labs
Next was some profiling on my wonderful 2x72” belt grinder which I basically just barely finished kitting out before the virus hit last month. Got everything most of the way to where I needed it, then I went to the heat-treat. I don’t have a heat-treating oven handy yet… OK to be fair I have a 50% constructed home-made one. But it’s been 50% completed for almost a year now. I’ve really got to get off my butt and finish up, but where will I find the time? That’s sarcasm, right there above. It can be tough to convey in prose. But I’m being very droll, honest. So my heat-treating process was a butane torch and a jar of canola oil that I collected after we did some quarantine fondue the other week. All I needed to do was to get the edge of the knife up into the orange range, then quench it into the oil. After that I sanded it down so I could see the metal and then heated the middle of the blade until the edge was starting to turn a golden color. Then I dipped the whole thing in the oil again.
The worst part of the process was that the oil smells of garlic and beef, and quenching glowing metal in it transferred the delicious smell to every corner of the garage. And I had not had lunch yet. After that, I spent a couple hours grinding and polishing the blade to about 2000 grit or so. I put a 10-degree bevel on one side (a “chisel grind”) and smoothed over the transition to make the leather-cutting a little easier. Next came the handle. I had one last piece of stabilized maple burl left in my pantry, so I grabbed that and threw it onto the little penmaking lathe that my dad foisted on us the last time we visited. He’s got like seven lathes and only really uses the great big one, so he’s been trying to get me to take one home for years. I’m glad I finally relented.
A couple hours of lathing later and I had something I was fairly happy with. My original plan for the bolster was to take a piece of brass or copper piping and hammer it into shape like what Torbjorn does in his video, but I found a copper pipe-cap that was just about the perfect size. After mangling the piece with a Dremel tool for a while, I threw it away and pulled out another one. I screwed that one up too. But the THIRD one turned out OK. Assembly was simply throwing a bunch of 5-minute epoxy at strategic spots and then cleaning up all the other spots that were covered in epoxy but weren’t supposed to be. So there we have it. A blacksmithed blade that never got anywhere near a hammer, forge, or tongs. Find me on Nova Labs Slack: @Pat Marstall
Flatline Forge Presents by Gari Jimenez-Lugo How can someone bring an 18th century blacksmith shop into the 21st century? A multiple camera video setup, of course! Gari is currently isolating at the Nicholas Creek Forge workshop and is going to be hosting a series of virtual blacksmithing classes in the near future. Classes will cover a wide range of skills and skill levels. A few class subjects include: Power Hammers, Forge Welding, Knifemaking, and a few other things that they’d like to keep secret until the class is announced. Gari Jimenez and Carter Hundley are both experienced demonstrators and journeyman smiths that have worked together on various demonstrations and events for a few years.
Nova Labs | May Newsletter | Page 23
SHOW US WHAT YOU GOT Be part of Show Us What You Got by posting pictures of what you make on the Slack channel—do not forget to add a caption that includes your full name! A selection of images on the channel will be added to our newsletter each month.
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16 7. Patrick waters End tables 8. Gari Jimenez-Lugo ½ inch socketed chisel made with wrought iron 9. Paul Warner Tier Planter 10. Tara Weaver Dragon egg bag 11. Richard Weil End-grain bowl 12. Jorge Jimenez Mechatronic eyes/eyelids
13. Samer Najia Replacement coupler for vacuum cleaner 14. Gari Jimenez-Lugo Display rack for knives 15. Samer Najia Mask 16. Andrew Albosta Echo Dot v1 wall holder. Pouch
Nova Labs | May Newsletter | Page 25
THE FUTURE OF INEFFICIENT TRANSPORTATION by Paul Chase
The Winded Dutchman. 3% efficient. 102% awesome.
For a long time now, the title for the least efficient velocipede was held by Wilbur and Orville Wright, having narrowly snatched the crown from Buster Keaton’s hobby horse. Fast-paced modern times have lost sight of the importance of inefficient transportation, but the visionaries at the American Visionary Art Museum in Baltimore, MD, have attempted to liven things up with their Kinetic Sculpture Race. While the race isn’t running this year, Nova Labs has got you covered!
Left: Buster’s walking with style. Top: The Wrights famously attempted to build a bicycle but ended up with a series of wheelless wonders that were exceptionally bad at touching the ground.
I present to you the anthroelectric hybrid pneumaticycle: the Winded Scotsman, which is truly one of a kind. The pedals of this mad machine are not connected to the wheels at all – instead, they drive a 3D printed pulley that drives an air compressor. While a bicycle achieves upwards of 95% efficiency, this air compressor is maybe 60% efficient – here we convert all that superfluous energy into heat and a lovely popping sound. That’s not all, though! Once the air’s in the tank it’s routed to a pair of dual-acting pistons doing their best impression of a piston steam engine, with an efficiency that’s certainly in the single digits - yes, the efficiency of this system is something like three whole percent! Cam-controlled valves keep the cylinders 90 degrees out of phase so that one is always pushing or pulling when the other is fully extended or withdrawn. The end result of all this is something like an enormous spring sitting between the pedals and the wheels – it’s a wonder that it works at all! After pedaling for 10 minutes to travel roughly one block, I decided to turn it into a hybrid with a pressure-control-switch and a large lithium battery, increasing the range from “downhill” to several miles! One glaring issue remains, and that is the heat generated by the compressor. Page 26 | May Newsletter | Nova Labs
The power input cycle. Pedals drive the chain drives the belt drives the compressor. The gearing increases the speed of the compressor, which is still nowhere near what the electric motor can do.
Why would someone build this? Because I can. Which is deceptive – when I started this project, I could NOT – in fact, I’m still just dabbling in how pneumatic components work. However, I can now read control valve diagrams and have a modicum of experience in the area – problems, control, and safety – which adds tools to my maker toolbox. Parts are insanely available now – the total cost of this project was under $300 – and it added to my knowledge base in computer-aided design as well. Furthermore, I hope the project inspires some of you to try something outlandish – because you’d be amazed at what you can do.
Top left: The control valves are at left - cams in blue - and the thin red tubes actuate the double-acting valves on the right. The pistons are mounted to the cam to transfer power to the wheel through the chain; rear cylinders are mounted in flexible plastic so they can bob up and down. Top right: Energy storage quiz - what holds more, the gigantic red air tank, or the comparatively small battery on the left?
Further Reading Unbeknownst to me, I’m not the only fellow working on this staggeringly important problem! Previously known as the Chainless Challenge, the problem of powering a bicycle without chains is used to inspire young engineers. Click here. Even these luminaries are mostly using hydraulics apparently due to some sort of wisdom they obtained with their mechanical engineering degrees. Nova Labs | May Newsletter | Page 27
HAPPENINGS IN MAY Some of the Main Attractions in May are below. Class names are clickable. 5/2/20 5/2/20 5/2/20 5/6/20 5/6/20 5/7/20 5/7/20 5/9/20 5/12/20 5/13/20 5/14/20 5/16/20 5/16/20 5/16/20 5/17/20 5/19/20 5/20/20 5/21/20 5/22/20 5/24/20 5/26/20 5/28/20
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Robotics Group Online Meetup STEAM4Kids - Kids Open Maker Meetup - Virtual EL: Scale Model Basics for Sci Fi Models: Lighting up a Starship - VIRTUAL WW: Wednesday Night Project Series: Box with Raised Panel Lid EL: Introduction to Basic Electronic Circuits - VIRTUAL BL: Blacksmith Series: Punch, Forgewelding, Slit and Drift LC: Laser Cutter 101 Red Tool Sign Off BL: Secrets of Damascus Steel: History and How-To (Online) CC: OnShape CAD101 - VIRTUAL EL: Introduction to Arduino Microcontrollers using TinkerCAD - VIRTUAL BL: Blacksmith Series: Intermediate Forgewelding, Rivets Robotics Group Online Meetup NVIDIA Jetson GPU Online Meetup STEM4Kids - Kids Open Maker Meetup BL: Blacksmith Series: Tongs BL: Blacksmith Series: Basics of Material Removal EL: Intro to Sensors with Arduino using TinkerCAD - VIRTUAL BL: Blacksmith Series: Hand Tools WW: Friday Night Project: Dadoes and Half-lap Joinery BL: Blacksmith Series: Coat Rack with Hand Forged Nails BL: Blacksmith Series: Forging a Blacksmith Knife BL: Blacksmith Series: Power Hammer
Calendar of Events Provided by Instructors and Randall Wood
Page 28 | May Newsletter | Nova Labs
POLICY MINDER Remember that Nova Labs is closed to both members and non-members for the duration of the COVID-19 crisis. Be assured that we will be sure to announce our re-opening through every channel we have!
SAFETY REMINDER We may have closed to encourage social distancing during the COVID-19 pandemic, but we still want you to be safe Makers! Follow all the same safety protocols in your home we require in the labs. And wash your hands for 20 seconds with soap and water frequently. We want to see everyone back with 10 fingers, full sight, and infection free!
CALL FOR VOLUNTEERS Virtual Classroom Instructors: We need instructors and hosts for online classes, demos, events or meetups. Paid or free events/classes welcome. Don’t know the tech? No problem, we can train you and mentor you. Contact Jennyfer or Farina to set up a Zoom walkthrough. Reach us on Slack or at events@nova-labs.org. Ask questions, take a leap of faith, a risk, try something different. We are makers, makers learn by doing and taking risks. We can also advise on very low cost equipment to get your home maker lab ready for videos and virtual learning.
Nova Labs | May Newsletter | Page 29
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