Overview
The Anchored Tsunami Ear Saver is a remix of the original Tsunami Ear Saver design. It includes brush-like extensions to keep the device in place in for users with long hair. This design was created by the Signal Processing and Instrumentation Section (SPIS) at NIH as a result of user feedback.
This design, like the original, is optimized to be laser cut from 1/32” acrylic. It costs $0.70 to produce and can be cut in 1 minute and 15 seconds. The thin acrylic used is easily cleaned with soap and water or hydrogen peroxide. We provide a standard size for the design which, based on feedback, fits most adult heads.
Background
The goals of the original Tsunami Ear Saver were a low-cost design that could be produced quickly and cleaned easily with commonly available supplies. None of the SPIS 3D printers could produce parts in a way that met all goals, so we developed a 2D design that could be cut from bulk acrylic on a laser cutter. The first designs provided many hooks to adjust for comfort and different mask types, but the hooks became tangled in long hair. This flaw inspired the original Tsunami Ear Saver, named after the shape of the mask strap hooks.
The Anchored Tsunami Ear Saver remix was inspired by feedback from a pilot user. The user liked the original design, however they asked for a feature that would secure the ear saver in place to prevent shifting. To help anchor the device in place, this design remix introduces brush-like features to the middle of the original design along the top and bottom edges. The short, straight features help reduce the risk of hair tangling during removal of the device, while the rounded tips provide additional comfort along the back of the head.
Material
The recommended material for the Anchored Tsunami Ear Saver is 1/32” Rowmark Value ADA Alternative Bright White Engraving Plastic. This material is flexible enough to conform to the back of the head while durable enough to not snap under the tension of mask straps. Unlike many 3D printed materials, the homogeneity of laser cut acrylic allows it to easily be cleaned with soap and water or hydrogen peroxide.
Production
Our Universal Laser Systems PLS6.150D laser cutter can cut a 12 x 24” sheet of 21 ear savers in about 26 minutes. Once the design is cut, the brush-like anchors need to be bent 90 degrees, so they are perpendicular to the ear saver. This can be accomplished with a heat gun using the following steps:
- Remove any protective film that is attached to the ear saver.
- Clamp the ear saver to a narrow, heat resistant surface so the anchors protrude off the edge.
- Use a heat gun to gently soften the anchors.
- As the anchors begin to soften and droop from gravity, use a flat piece of heat resistant material to bend the anchors 90 degrees.
- Rotate the ear saver, and repeat steps 2 to 4 for the opposite set of anchors.
- Let the ear saver cool, and then wash it with soap and water before use to remove any residues from the cutting process.
Please remember to use the proper personal protective equipment (PPE) and safety procedures when using a heat gun to post-process ear savers.
Alternative Manufacturing
While this design is intended to be laser cut from 1/32” acrylic, it could also be produced by other means. We include STL files for the design, with anchors already bent in the correct orientation, so that it could be produced on 3D printers. We encourage users, however, to consider material properties (especially biocompatibility), production times, and sanitization needs when choosing an alternative manufacturing method.
Design Files
A variety of design files are provided to make the design accessible to a range of users. This package includes the final design as a SolidWorks model (sldpt), Corel Draw (cdr), Dxf, and STL.
Disclaimer
The device described here along with the accompanying files is experimental in nature and has not received regulatory approval for use in humans or any other use. CIT does not warrant its use for any purpose and disclaims all liability for its use. By using the enclosed plans, the user agrees to accept all liability.
