COVID-19 Engineering Response Team

Adapts an ambient-air personal protection system into a sealed PAPR

Need

Shortage of powered air-purifying respirator (PAPR) systems, which provide greater protection than an N95 respirator and face shield

Project Summary

The design seals the permeable part of a commercial surgical hood with transparent film and seals the fan on top of the helmet with a 3D-printed manifold so that air can be pulled through two in-line ventilator filters. This creates positive pressure inside the hood with filtered, not ambient, air.

Over 80 institutions have requested design files and nearly 30 licensing agreements have been completed.

Team

• Lead: Melissa Erickson (Surgery, Fuqua WEMBA)
• Members: Eric Richardson (BME), Paul Fearis (BME), Chip Bobbert (OIT), Mark Palmeri (BME)

Project Partner

• Precision Air Technology

Media

• Duke Today: 3D Printing to Give Medical Teams the Highest Level of Protection »
• Journal of Arthroplasty: Helmet Modification to PPE with 3D Printing During the COVID-19 Pandemic at Duke University Medical Center: A Novel Technique

A robust injection-molded headband attached to a thermo-formed shield

Need

Supplemental supply of reusable face shields.

Summary

• 30,000 units manufactured; goal to produce 75,000 units
• Assembly is being completed by a team of more than 20 volunteers 
• More than 100 downloads of license request; nearly 50 license agreements signed

Team

• Lead: Chip Bobbert (Office of Information Technology-OIT)
• Members: Evan Levine (OIT), Paul Fearis (BME), Mark Palmieri (BME) and Ryan J. Shaw (School of Nursing)

Project Partners

• Beechwood Metal Works
• Nike
• Protolabs

Media

• Duke Today: Solving Pressing Challenges: 3D Printing of Medical Grade Face Shields »

Need

A team investigating aerosolized virus in COVID 19 patient rooms requested design assistance for a clip for an aerosol sampling device.

Summary

• Design completed
• First part has been produced
• Approvals received
• Clinical implementation and manufacturing ramp-up are in process

Team

• Lead: Chip Bobbert (OIT)
• Members: Lucas Rocha-Melogno (CEE)

Media

Needs

• Increase usage of non-invasive ventilation by COVID-19 patients

• Minimize health care-worker exposure to respiratory droplets from COVID-19 patients

Project Summary

• The team has designed a tent-like structure with an aluminum frame, full zipper opening, sleeve/glove and double-door compartments, and an HVAC system with negative pressure and HEPA filtration rate using nonmedical filters
• Final particle/filter testing performed with partner Precision Air Technologies—and passed
• Request for Emergency Use Authorization submitted to the U.S. Food and Drug Administration (FDA)
• In manufacturing ramp-up—6 units completed

Team

Lead: Konstantinos Economopoulos (Surgery/BME)

Members:

• School of Nursing Faculty: Jackie Vaughn, Ryan Shaw
• MEMS Faculty: W. Neal Simmons
• BME Faculty: Paul Fearis, Eric Richardson
• Engineering Students: Ben Wesorick, Theresa Thompson, Kanishka Patel, Shikha Sharma, Yaas Bigdeli, Max Sondland, Dimitrios Bailas

Project Partners

• Polyzen
• Precision Air Technology

Media

Needs

• Shortage of powered air-purifying respirator (PAPR) systems, which provide greater protection than an N95 respirator and face shield
• Duke and the Durham VA hospitals have supplies of older PAPR hoods which cannot be used because they do not connect to the PAPR pumps now in use

Project Summary

• The team has developed two 3D-printed adaptors, which have undergone testing
• The adaptors will allow two different pumps to be connected to three different PAPR hoods
• Final designs completed and delivered to Durham VA Hospital

Team

• Lead: Alejandro Pino (Pulmonology)
• Members: Eric Richardson (BME), Chip Bobbert (OIT), Paul Fearis (BME), Neal Simmons (MEMS)

Illustration

Need

A method to allow one ventilator to support two patients, even if two COVID-19 patients have different pulmonary compliances—to be used only in emergencies when other options have been exhausted.

Project Summary

• The team has developed an easy-to-use ventilator output splitter that can be combined with novel airflow resistors
• The splitter and flow resistors are 3D printed from biocompatible materials
• Decision-support mobile app developed with CrossComm Inc.
• Request for Emergency Use Authorization has been submitted to the U.S. Food & Drug Administration (FDA)

Team

Lead: Muath Bishawi (Surgery/BME)

Members: Ken Gall (EngEn); George Truskey and Amanda Randles (BME); David MacLeod, Anne Cherry, Jhaymie Cappiello (Anesthesiology); Amy Alger (Surgery)

Project Partners

• CrossComm—founded by a Duke Computer Science graduate
• Restor3d—a Duke Engineering faculty startup
• LEGEND Technical Services Inc.

Media

Need

During intubation procedures, health care providers need shielding from respiratory droplets from COVID-19 patients.

Project Summary

• Testing a design from outside of Duke
• Feedback communicated to the manufacturer
• Duke clinicians viewed existing solutions as adequate—project on hold

Team

• Leads: Muath Bishawi (Surgery/BME), Kostantinos Economopoulos (Surgery/BME)
• Members: Chip Bobbert (OIT), David MacLeod (Anesthesiology), John Whittle (Anesthesiology)

Need

A supplemental supply of nasal swabs for the diagnosis of COVID-19.

Summary

• Team is investigating the 3D-printed nasal swab developed by USF Health, Northwell Health and Formlabs
• Clinical feedback received
• Manufacturer identified

Team

• Lead: Chip Bobbert (OIT)
• Members: Eric Richardson (BME), Donna Crenshaw (MEDx), Cameron Wolfe (Infectious Diseases), Nancy Henshaw (Pathology)

Project Partner

• Yukon Medical

Need

Safely deliver high-flow oxygen to COVID-19 patients without creating contagious aerosols.

Summary

• Assessing a snorkel mask provided by a third-party company
• Testing completed at the Duke Center for Hyperbaric Medicine and Environmental Physiology
• Working with partner to 3D-print and test snorkel mask design

Team

• Lead: Alejandro Pino (Pulmonology)
• Members: Eric Richardson (BME), Donna Crenshaw (MEDx)

Partner

• Hondajet

Need

Create 200 dispensing stations for hand sanitizer to support the opening of Duke research laboratories.

Summary

• Working on prototypes that include a stand and refill cartridges
• Tray designed and built to store and transport refilled cartridges
• Stand prototype received positive feedback
• Integrating design with local manufacturer to scale

Team

• Leads: Eric Richardson (BME), Donna Crenshaw (MEDx), Chip Bobbert (OIT)
• Members: Collin Duckett, John Noonan and Scott Johanns

Need

To remotely press the "100% Oxygen Increase" button on a ventilator. This would enable a patient to receive increased oxygen flow without requiring a clinician to don full personal protective equipment.

Summary

• Wired mechanism solution path chosen after initial meeting with respiratory therapist
• Code, circuit diagram, CAD and bill of materials produced for wired mechanism
• Prototyping has begun

Team

• Lead: Alejandro Pino (Pulmonology)
• Members: Parker Faircloth-Henise (BME), Katherine Waugh (ME), Michael Wong (BME)

Media

Need

Reduce aerosolized particle formation and protect staff members by minimizing the number of times an endotracheal tube (ET) must be disconnected.

Summary

• The team has proposed two designs: a Y-joint that adds a bronchoscope port, and a Y-joint-plus-connector
• Next steps include: 3D printing of designs for feedback from respiratory therapists, consideration of a compression fitting to reduce unintentional detachments and of a clip to secure the connection

Team

• Lead: Alejandro Pino (Pulmonology)
• Members: Taylor Huie, Aidan Therien

Media

• Clear Earloop Face Mask — For Duke Occupational and Environmental Safety Office (OESO) and the Disability Management System. A provider who sees pediatric patients at Lenox Baker Children's Hospital and Duke Children's Hospital and Health Center has requested an ADA accommodation for a clear-front earloop mask.
• Slit Lamp Shield — Ophthalmologist Mark Goerlitz Jessen has requested a shield for a slit lamp to protect patients and providers from airborne infectious particles that may be transmitted during an eye exam.

1. Validation of need with hospital administration
2. Survey existing designs and/or create new designs
3. Pilot manufacturing/prototyping
4. Testing/review with health care professionals
5. Risk assessment and documentation
6. Manufacturing
7. Approval for implementation
8. Clinical implementation