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Design Processes of the Intubation Cabinet

Our Design Director, Can Onart, wrote the design processes of the Intubation Cabinet, which we produced for hospitals as part of the Support from Us project.

Design Processes of the Intubation Cabinet

The appearance of Covid-19 cases in many countries before Turkey had a critical meaning for us. We were able to have prior knowledge of the needs that emerged in the form of excessive density and supply problems in hospitals. Thanks to the open-source sharing culture, many designs for these needs were available on the internet. While sending the visor request, we had collected on Destekbizden.org to the hospitals; our operation team received feedback on new needs. One of these needs was the intubation cabin. 

When we first found the open-source intubation cabinet design, we saw that the design was made for the CNC router and the material used was designed for 3mm materials. To make our first try out of 3mm transparent plexiglass, we made the design suitable for laser cutting. When we produced and assembled it, we saw that the cabinet was not strong enough because it would be subject to frequent sudden changes in continuous use. For this reason, we started our revisions to use 5mm material for the next prototype manufacturing. We designed this design to be suitable for both CNC Router and CNC Laser manufacturing. 

After the design was finished, we ordered two different materials for trial. One was 5mm cast plexiglass and the other was 5mm extrusion plexiglass. However, we saw that the extruded plexiglass shows size differences along with the plate. While the material thickness was 4.8 mm in one part of the plate, this value could go up to 5.4 mm in another part of the plate. For this reason, we decided to produce only from cast plexiglass because using materials with high measurement precision was better for manufacturability and assembly. We created our first three cabins and delivered them to different hospitals as assembled (glued). 

We started to receive feedback with the use of the first boxes delivered. The first feedback we received was that the viewing angle was limited by design. In order for the patient in the cabin to be seen comfortable by the doctor, we brought the upper part, which has a low slope, to a more inclined form. 

The second feedback we received was that the holes through which the doctors’ hands went to the patient damaged their wrists during the intervention. For this reason, we produced a protection apparatus from TPU material to surround the holes and mounted it by inserting it into those areas. We delivered three more intubation cabinets built in this direction to hospitals and updated our design according to the new feedback. This time, we received feedback that some patients may require the intervention of 3 healthcare professionals in emergencies. For this reason, we designed one more hole that can be opened and closed on the plates on the right and left of the cabinet. 

The following feedback was that the cabinet did not fit well on the broad-shouldered patients, creating difficulties during the procedure. For this reason, we completed our design by opening semi-circles in the lower corners of the open part of the cabin, where the shoulders can enter. 

When shipping the intubation cabinets began, logistical problems started to arise. The package size of one assembled intubation cabinet was 60 x 50 x 45 cm. These sized were not suitable for sending by courier. It was hazardous to ship the product by courier. It was nearly impossible for us to send these cabins out of town. For this reason, we have designed a kit with a lock system that healthcare workers can assemble in the hospitals to which the assembly is sent. After removing the protective nylons on the transparent plates, they could attach the pieces together and then quickly place the lock mechanisms that we produced in 3D printers to fix the product from 6 corners. 

The package version of this product has become 60 x 45 x 8 cm with this change. We have completed our product by adding an installation manual to each cargo package so that the assembly of the packaged products can be easily achieved. If you own a workshop capable of producing an intubation cabinet, you can download the files on Github and carry out manufacturing. You can also access the installation guide on Github and watch the installation video on Youtube.

Equipment Required for Manufacturing: 

Laser Cutting Machine 

A 3D printer that can produce with TPU and ABS material (if you do not have these parts, we can make these parts and send them to you. For request, you can send an e-mail to covid@tridi.co) 

Materials Required for Manufacturing: 

5mm thick Plexi material 

ABS and TPU filament (Print parameters of TPU material: It should be printed in a vase model, and the extrusion setting should be 0.6 or 0.7 mm) 

4 metric 15 mm long bolts, suitable washer and fibre nut for this bolt.

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