Integrated Polymeric Face Shield with On-Demand Hand Sanitisation for Infection Control in Dentistry

Background: Persistent challenges in healthcare infection control, particularly the need for rapid hand hygiene during continuous patient care, highlight limitations of current personal protective equipment (PPE). We developed a lightweight face shield integrating a disinfectant reservoir to enable immediate point-of-care hand sanitisation. Methods: A dual-function system was designed comprising a polyethylene terephthalate glycol (PETG) visor (23 × 23 cm, 0.20 mm) and a modular disinfectant reservoir (25–100 mL). Components were fabricated using CAD, 3D printing, and PETG forming. The reservoir features a touch-activated, self-sealing valve delivering approximately 3 mL per activation. Benchtop testing assessed dosing consistency, leak-tightness, attachment security, material compatibility with alcohol-based disinfectants, and durability. Results: The visor weighed 13.4 g, with total system mass of 103.4 g (empty) and 203.4 g (maximum fill). Cervical torque increased from 0.084 to 0.282 N·m, supporting continuous wear for 60–90 minutes. Testing confirmed consistent dosing, reliable resealing, leak-free performance, and PETG stability after disinfectant exposure. Conclusions: This dual-function visor integrates facial protection with immediate hand sanitisation, addressing critical infection-control challenges in dentistry. Its low cost, reusability, and modular design support chairside use and mobile dentistry, while enabling future integration of wearable sensors.