Note: this includes LaFactoria3D's original mask parts that this is designed to fit. It's a great design, and I include it here because they have since updated the mask base in a way this cannot fit. If you feel their updated version provides better protection I urge you to use it instead.

Replacement cap for LaFactoria3D's COVID-19 MASK

While printing mask parts for Lowell Makes I wanted to find some way to help healthcare workers relieve some stress. Making replaceable caps seems the best way to offer an adjustment; these clip right onto existing masks without interfering with function and maybe they can lighten the mood in pediatrics.

This was a special request for a young man who's very frustrated having to wear his mask but loves this character, so how could I pass up: Dusty Crophopper. It might be a little cumbersome at full size, but it should scale well with a little cleanup for the moving parts. I haven't had a chance to print it yet but the parts slice well in Cura.

Assembly:

Instructions on how to assemble the rest of the mask efficiently and good materials to use can be found here, thanks to GiveWave Studios: https://youtu.be/9ItpExBEieY

As for the decorative cap:

• I recommend printing with the blades vertically if you have the time to assemble it, as that'll produce a cleaner print. The assembled propellers will still spin, but at full scale the long-blade version doesn't fit on some beds (and they'll need a lot more cleanup).
• The body can be printed pointing up or pointing down; nose-down uses less material for supports but they'll be harder to remove, and nose-up will require less cleanup.
• Test-fit all the pieces first, just in case the tolerances are not quite right.
• Once you're satisfied the blades fit inside the nose cap and everything is painted, glue them in with the back plate holding them in place.
• The sleeve should be glued inside the main body so the extending sleeve is free from any glue.
• Then slip the axle through the sleeve from the inside so it's glued only at it's tip, where it fits inside the assembled nose cap.
• Lastly (or firstly if you want, I'm not your mom) glue in the exhaust ports on the sides facing toward the back.
• The assembled cap should fit snugly onto the mounting bracket, which in turn snaps onto the main mask itself.
• Run with arms fully extended and make engine noises. I haven't watched the movie, but I assume it's what Dusty would want.

I hope it's recognizable but having not seen the Planes movie yet, having a hard time finding different perspectives and needing to widen his face to fit the mask might be distracting. If you find any issues with it or it my instructions are not clear, please let me know so I can make adjustments.