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King WP, Amos J, Azer M, Baker D, Bashir R, Best C, Bethke E, Boppart SA, Bralts E, Corey RM, Dietkus R, Durack G, Elbel S, Elliott G, Fava J, Goldenfeld N, Goldstein MH, Hayes C, Herndon N, Jamison S, Johnson B, Johnson H, Johnson M, Kolaczynski J, Lee T, Maslov S, McGregor DJ, Milner D, Moller R, Mosley J, Musser A, Newberger M, Null D, O’Bryan L, Oelze M, O’Leary J, Pagano A, Philpott M, Pianfetti B, Pille A, Pizzuto L, Ricconi B, Rubessa M, Rylowicz S, Shipley C, Singer AC, Stewart B, Switzky R, Tawfick S, Wheeler M, White K, Widloski EM, Wood E, Wood C, Wooldridge AR. Emergency ventilator for COVID-19. PLoS One 2020; 15:e0244963. [PMID: 33378363 PMCID: PMC7773325 DOI: 10.1371/journal.pone.0244963] [Citation(s) in RCA: 16] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/21/2020] [Accepted: 12/18/2020] [Indexed: 01/15/2023] Open
Abstract
The COVID-19 pandemic disrupted the world in 2020 by spreading at unprecedented rates and causing tens of thousands of fatalities within a few months. The number of deaths dramatically increased in regions where the number of patients in need of hospital care exceeded the availability of care. Many COVID-19 patients experience Acute Respiratory Distress Syndrome (ARDS), a condition that can be treated with mechanical ventilation. In response to the need for mechanical ventilators, designed and tested an emergency ventilator (EV) that can control a patient's peak inspiratory pressure (PIP) and breathing rate, while keeping a positive end expiratory pressure (PEEP). This article describes the rapid design, prototyping, and testing of the EV. The development process was enabled by rapid design iterations using additive manufacturing (AM). In the initial design phase, iterations between design, AM, and testing enabled a working prototype within one week. The designs of the 16 different components of the ventilator were locked by additively manufacturing and testing a total of 283 parts having parametrically varied dimensions. In the second stage, AM was used to produce 75 functional prototypes to support engineering evaluation and animal testing. The devices were tested over more than two million cycles. We also developed an electronic monitoring system and with automatic alarm to provide for safe operation, along with training materials and user guides. The final designs are available online under a free license. The designs have been transferred to more than 70 organizations in 15 countries. This project demonstrates the potential for ultra-fast product design, engineering, and testing of medical devices needed for COVID-19 emergency response.
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Affiliation(s)
- William P. King
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Carle Illinois College of Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Jennifer Amos
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Carle Illinois College of Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Magdi Azer
- Applied Research Institute, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Daniel Baker
- Fast Radius, Chicago, IL, United States of America
| | - Rashid Bashir
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Carle Illinois College of Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Catherine Best
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Eliot Bethke
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Carle Illinois College of Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Stephen A. Boppart
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Carle Illinois College of Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Elisabeth Bralts
- Siebel Center for Design, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Ryan M. Corey
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Rachael Dietkus
- Siebel Center for Design, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Gary Durack
- Tekmill, Champaign, IL, United States of America
| | - Stefan Elbel
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Creative Thermal Solutions, Urbana, IL, United States of America
| | - Greg Elliott
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Jake Fava
- Siebel Center for Design, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Nigel Goldenfeld
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Molly H. Goldstein
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Courtney Hayes
- College of Veterinary Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Nicole Herndon
- College of Veterinary Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Shandra Jamison
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Blake Johnson
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Harley Johnson
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Mark Johnson
- Carle Illinois College of Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Carle Foundation Hospital, Urbana, IL, United States of America
| | | | - Tonghun Lee
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Sergei Maslov
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Davis J. McGregor
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Derek Milner
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Ralf Moller
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Jonathan Mosley
- College of Agricultural, Consumer, and Animal Sciences, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Andy Musser
- Creative Thermal Solutions, Urbana, IL, United States of America
| | | | - David Null
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Lucas O’Bryan
- Siebel Center for Design, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Michael Oelze
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | | | - Alex Pagano
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Siebel Center for Design, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Michael Philpott
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Brian Pianfetti
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Alex Pille
- Fast Radius, Chicago, IL, United States of America
| | - Luca Pizzuto
- Fast Radius, Chicago, IL, United States of America
| | - Brian Ricconi
- Creative Thermal Solutions, Urbana, IL, United States of America
| | - Marcello Rubessa
- College of Agricultural, Consumer, and Animal Sciences, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Sam Rylowicz
- Fast Radius, Chicago, IL, United States of America
| | - Clifford Shipley
- College of Veterinary Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Andrew C. Singer
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Brian Stewart
- Carle Foundation Hospital, Urbana, IL, United States of America
| | - Rachel Switzky
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Sameh Tawfick
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Matthew Wheeler
- College of Agricultural, Consumer, and Animal Sciences, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Karen White
- Carle Illinois College of Medicine, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
- Carle Foundation Hospital, Urbana, IL, United States of America
| | - Evan M. Widloski
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Eric Wood
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
| | - Charles Wood
- Fast Radius, Chicago, IL, United States of America
| | - Abigail R. Wooldridge
- Grainger College of Engineering, University of Illinois Urbana-Champaign, Urbana, IL, United States of America
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