Nova Labs PPE Intubation Tent

by Bo Wernick

In early April 2020, the Nova Labs volunteer community, in cooperation with medical professionals, began developing a low cost foldable intubation tent. It was inspired by the popularity of large acrylic cases designed to prevent the spread of aerosolized particles from Covid-19 patients infecting medical professionals. The Nova Labs community was tasked with developing a lightweight and collapsible version that could meet the complex needs of the medical environment while reducing the storage footprint and high cost of the existing products.

Intubation without, Personal Protective Equipment (PPE)

The process began with a requirement-gathering effort between Bo Wernick at Nova Labs and Amy Keim, PA-C, who was working as a medical professional in the Washington DC area. Those requirements led to a brainstorming session where a variety of challenges were identified with existing solutions. After some group brainstorming with a team of Nova Labs volunteers, a concept began to take shape, and a plan was put into motion. The development process began with several “fit check” prototypes. These tools were built to rapidly gather information about access port locations, size and shape optimizations, and niche features like sealing ports, enabling removal of the device while the patient was connected to machines, and attaching the tent firmly to the patient’s stretcher or gurney. The initial fit check tools were cardboard, hot glue, and plastic sheeting. The fit check tools were tested in the medical environment and new measurement feedback was provided.

Fit check tools used to identify size and shape requirements.

Fit check tools used to identify size and shape requirements.

Fit check tools used to identify size and shape requirements.

With the information from the fit check tools, the Nova Labs team was able to create a “form and function” prototype to better evaluate the final design approach. Some additional refinements were noted, such as adding velcro slits. These slits would allow the entire apparatus to be removed and replaced without disturbing tubes and wires that connected the patient to machines in the room through the various access ports.

The form and function prototype made from aluminum rods and 3D printed corner brackets. The overlay is made from heat-sealed vinyl with velcroaccess ports.

The form and function prototype made from aluminum rods and 3D printed corner brackets. The overlay is made from heat-sealed vinyl with velcroaccess ports.

The form and function prototype made from aluminum rods and 3D printed corner brackets. The overlay is made from heat-sealed vinyl with velcroaccess ports.

The final step was preparing for beta unit manufacturing. These first 50 units would be used to help medical professionals stay safe on the front lines of the Covid-19 pandemic while gaining valuable feedback on the product from real world end users.

The Nova Labs team ran several manufacturing tests to determine the most cost- and time- efficient ways to seal the sheets of vinyl, cut and bend the aluminum rods, 3D-print the corner brackets, and make videos and instructions to allow our extended volunteer community to participate in the manufacturing effort. The NL community also developed a budget and designed a fundraising effort to fund the production of fifty units.

Engineering drawings for the substructure.

Completed 3D printed corner bracket.

The Intubation Tent is currently in beta testing with the first 50 units going to 3 hospitals. We recognize the need for this product and so we are planning for larger production runs with the support of vendors around the country, and eventually globally. Our goal is to be able to produce enough product for any organization who wants it at an affordable price. We plan to donate a portion of the proceeds back to Nova Labs to help them continue to support their amazing maker community. Check link to read more about Airway Procedure Tent Information

https://www.nova-labs.org/apt/