Use of 3D printed connectors to redesign full face snorkeling masks in the COVID-19 era: A preliminary technical case-study

Abstract

The COVID-19 pandemic resulted in severe shortages of personal protection equipment and non-invasive ventilation devices. As traditional supply chains could not meet up with the demand, makeshift solutions were developed and locally manufactured by rapid prototyping networks. Among the different global initiatives, retrofitting of full-face snorkeling masks for Non-Invasive-Ventilation (NIV) applications seems the most challenging. This article provides a systematic overview of rapid prototyped - 3D printed - designs that enable attachment of medical equipment to snorkeling masks, highlighting potential and challenges in additive manufacturing. The different NIV connector designs are compared on low-cost 3D fabrication time and costs, which allows a rapid assessment of developed connectors for health care workers in urgent need of retrofitting snorkeling masks for NIV purposes. Challenges and safety issues of the rapid prototyping approach for healthcare applications during the pandemic are discussed as well. When critical parameters such as the final product cost, geographical availability of the feedstock and the 3D printers and the medical efficiency of the rapid prototyped products are well considered before deploying decentralized 3D printing as manufacturing method, this rapid prototyping strategy contributed to reduce personal protective equipment and NIV shortages during the first wave of the COVID-19 pandemic. It is also concluded that it is crucial to carefully optimize material and printer parameter settings to realize best fitting and airtight connector-mask connections, which is heavily depending on the chosen feedstock and type of printer.

Experiencia de uso de una máscara de snorkel adaptada como equipo de protección personal en la pandemia por COVID-19. Serie de casos

“…A laboratory in Barcelona (Spain) prints 3D adapters/coupling valves for the use of the snorkeling mask as PPE in the Hospital Clínico Universitario de Valladolid and the Hospital Universitario Infanta Leonor, which have had positive results, and the printed part fits snugly with no apparent leaks (13). However, the air outlet port of the masks varies depending on its reference and manufacturing house, so the adapter must be designed (14,15).…”

Supply chain disruptions and resilience in manufacturing industry during covid-19: Additive manufacturing intervention in perspective

“…Many components used in machines and devices can be replaced by 3D-printed parts. The use of high-performance 3D printing materials such as PEEK, ULTEM, or PC allows the manufacturing of parts that have very good mechanical properties (Profili, Brunet, Dubois, Groenhuis & Hof, 2021). Parts from these filaments can be chosen as metal parts replacement.…”