ROYAL OAK, Mich. – For De La Salle Collegiate alumnus Phil Zimny his 3D printer was a way to assist his alma mater’s robotics team. But during these unprecedented times, he is using his printer to help frontline healthcare workers in their fight against COVID-19. 

A self-employed computer programmer, Zimny consulted with lifelong friend and De La Salle science teacher Rob Black, on his idea to make face shields and donate them to metro Detroit hospitals. Black also serves as a moderator for the AutoPilots, the school’s successful robotics team. 

“Hospitals have had a huge shortage of personal protective equipment,” Zimny said. “Materials are in short supply, and people around the world are trying to solve the problem, such as using the acetate sheets teachers use to use on overhead projectors. The acetate is thinner, but with some modifications, it can work.”

Working alone in his home, he made a template for the clear shields, and then physically bends each shield to fit a plastic headband. Elastic purchased from a craft store is then used to complete the shields. 

Zimny estimates each completed shield costs about $2.50. 
 
“I’m really just donating my time,” Zimny said. “It’s not a lot of money.”

So far, completed shields have been donated to area hospitals, including Children’s Hospital of Michigan, in Detroit and Troy. 

While social distancing and the governor’s stay-home order prohibits AutoPilots team members from participating in the physical process, they did manage to play a small – yet significant role – in helping manufacture the shields.

With the surplus budget left from this year’s suspended robotics season, Black asked school Principal Nate Maus if the funds could be used to purchase materials to build the face shields. 
 
“The Robotics team leaders had a great idea to create face shields and donate to our frontline medical personnel,” Maus said. “It was a great way to use the resources they had to help those who needed it most. They are truly a reflection of the Lasallian character we try to instill in our students every day.” 

A robotics team mentor, Zimny enjoyed work with De La Salle students and his 3D printer.  

“I got involved with the robotics team because it was a way to pay back to the kids,” he said. “I saw how useful 3D renderings were. It's been a tool for me to learn a skill I don’t have.” 

With De La Salle’s donation, Zimny purchased specialized filament and clear plastic and is printing out the headband portion on his printer. He has produced 70 headbands used on the shields.

“It took a little time to get the right speed and temperature,” he said. “You don’t want the finished product to look like a spaghetti monster.” 

Zimny’s said his love for computer programming began in high school with classes taught by teachers Richard Dobryzinski and Tony DeSantis. Learning basic programming in DeSantis’ class and general-purpose programming from Dobryzinski led him to college at Loyola of Chicago.

“I didn’t appreciate how good those courses were until I got into college,” Zimny said. 

The De La Salle Dads Club donated many of the tools that AutoPilots members use to build out the robots that are used in local and state competitions. But Black, who has now ordered his own 3D printer, said the school could use more assistance from alumni for things like 3D printers, metal, and wiring.