Ryan Koschay started learning about 3D printing in high school so when the Novel Coronavirus pandemic hit, he was ready to help.
A mechanical engineering major at Michigan State University, Koschay aligned his skills, resources, and sense of service to create and donate a combined 1,218 face shields and face masks to help health care workers. He has continued those efforts for friends and family by printing another 260+ in Personal Protection Equipment (PPE).
"My family and I saw a TV story that Print Force in Okemos was recruiting volunteers with 3D printing skills. I had plenty of 3D experiences and was sitting around doing nothing," he said. "I felt that the skills I've acquired since high school shouldn't be idle during this health crisis, so I thought I should help if I can."
Koschay, who lives in Grand Ledge, began making PPE as a volunteer. He had bought his first 3D printer for design competitions as a senior in high school and put that printer to work after connecting with Print Force in the TinkrLAB at the Meridian Mall in Okemos.
"I started printing the band for face shields using a plastic polymer (PETG) that was flexible enough to mold to a wearer's head but strong enough to hold its rigidity. I was using a design with eight prongs to hold the shield on. Then, I started printing a molded face mask using a more rigid polymer (PLA) that conformed to the shape of the mouth and nose. The design allows for an air filter to pop in and out for easy filter replacement and mask sanitation."
As his work progressed, he turned to his internship mentors at the Burgess Institute for Entrepreneurship and Innovation in the MSU Broad College of Business to join in the support.
"My internship started backing me by loaning me two 3D printers and providing filament, which helped in the production," Koschay continued. "Then I bought two more 3D printers to increase production capacity."
Throughout the project, Koschay continued to troubleshoot and optimize his 3D printing techniques to further increase production rates as well as production quality.
One of the ways Koschay groomed his 3D printing skills was the class, ME280, which was taught by mechanical engineering academic specialist Katherine Stevenson. Koschay is a teaching assistant in ME280, as well as Stevenson's 3D printing assistant.
"Her class helped me grow my skills as a CAD Designer and become a better engineer in general," he said. "That class and the experiences I've had working for her, as well as having her as the adviser for my ASME IAM3D team this past year, have helped me to better visualize and understand how to create designs and optimize them in CAD and 3D printer slicing software for the best Additive Manufacturing results."
Koschay will begin his junior year in mechanical engineering this fall. He will be returning as a trumpeter in the MSU Spartan Marching Band and Spartan Brass. He is involved in MSU's Unmanned Systems Group as the ASME and FPV Racing Team captain. He is also an Eagle Scout.
In all, Koschay has spent almost $2,000 including more than $800 out of his own pocket during the PPE project.
"Helping health care workers stay protected makes me feel like I'm using my skills in the best way possible. I'm helping our community and our nation get through this pandemic. Knowing that I did what I could to help flatten the Coronavirus curve feels great," he added.