Advanced Manufacturing Design of an Emergency Mechanical Ventilator via 3D Printing—Effective Crisis Response

Nowadays, there is a market need that is pushing manufacturers to support more sustainable product designs regardless of any crisis. Two important lessons that society inferred from the COVID-19 pandemic are that the industry needs an improved collaboration efficiency that can handle such emergencies and improve its resource conservation to avoid having shortages. Additive manufacturing technologies use 3D object scanners to direct hardware to deposit material, layer upon layer, in precise geometric shapes, and are positioned to provide a disruptive transformation in how products are designed and manufactured. They can provide for the planet in fighting against crisis from a materials and applications perspective. In this context, the optimization and production of emergency ventilators in health systems were investigated with plans for 3D printing received from the University of Illinois Urbana–Champaign. An evaluation of the printability of CAD files and a partial redesign to limit dimensional variability, acceptable surface finish, and a more efficient printing process were performed. Six parts of the design were redesigned to make printing easier, faster, and less expensive. In the case of the O2 inlet attachment, the necessary supports were difficult to remove due to the part’s geometry, leading to redesign. The modulator top and bottom part, the patient tee, the manometer body, and the pop-off valve cap were also redesigned in order to avoid dimensional variability and possible rough surfaces. Metallic and thermoplastic composite ventilators were produced and then tested in real operating conditions, such as in a hospital setting with a realistic oxygen supply. The preliminary findings are promising compared to the initial design, both in terms of construction quality and performance such as exhalation rate adjustment and emergency valve operation. Also, a combination of manufacturing technologies was evaluated. The modifications allowed optimal casting (injection molding) of the parts and therefore faster production, instead of printing each part, when high output is required