Design, manufacturing, and testing of 3D-printed fittings for ergonomic helmet CPAP devices: a case study
Paweł Płatek, Natalia Daniel, Kamil Cieplak, Marcin Sarzyński, Janusz Kluczyński, Grzelak Krzysztof, Łukasz Wróblewski
TL;DR
Researchers designed and tested 3D-printed parts for a helmet CPAP device to address shortages during the pandemic, showing that 3D printing can reliably produce medical equipment.
Contribution
A novel design and validation of 3D-printed medical fittings for hCPAP systems using rapid, localized manufacturing.
Findings
3D-printed ABS Medical components showed no microplastic release under high airflow, ensuring safety.
CFD-optimized diffuser geometry improved air distribution and reduced noise in the helmet system.
Clinical trials with 120 participants confirmed ergonomic performance, low noise, and high comfort.
Abstract
This study presents the design, optimisation, and experimental evaluation of additively manufactured fittings for a custom helmet continuous positive airway pressure (hCPAP) system. The project was initiated as a rapid response to the shortage of respiratory support equipment during the COVID-19 pandemic. The inlet and outlet connectors of the helmet were redesigned to comply with the EN ISO 5356–1:2015 standard, reduce mass, and simplify assembly, while ensuring functional reliability and patient comfort. Components were fabricated using fused filament fabrication (FFF) and selective laser sintering (SLS) with medical-grade ABS, TPU-95A, and PA 2200 materials. A comprehensive assessment of material safety was performed, including tests for potential particle detachment under high-flow air conditions. Results confirmed that ABS Medical printed without active cooling exhibited no…
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Taxonomy
TopicsInfection Control and Ventilation · Inhalation and Respiratory Drug Delivery · Respiratory Support and Mechanisms