I’ve made a few hundred of the ear savers from the provided file and dropped them all off to my friends who work as medical personnel. I asked for honest feedback. The biggest complaint is the rigidity of the acrylic. I then went on to make some of the other styles and used what I had on hand. I’ve also ordered some other materials to test out.
Curious what others have heard from their recipients. I’m trying to find both the best material and design
I have not heard back yet but my own observations tell me that flexible is more comfortable.
Did you see my post on flex material?
Thank you, Mark. I missed your post previously. Extremely informative. I’ll be ordering some.
I also had a local plastics shop willing to donate some samples for me to test. If anyone is familiar with them, would love some guidance.
1/8" thickness such as ABS, HDPE, Foamed PVC, and VHMW
!! Always look things up before putting them into your 
ABS safe but mixed results
HDPE safe but as a rule, poor results
Foamed PVC !!! This will kill you and your machine!!! I hate it when people put lots of ! in but this is for reals.
VHMW safe with mixed results.
The first rule of laser club, never put any chlorinated plastic into a laser. PVC is the most common but not the only one it releases chlorine gas when cut.
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