DESIGN AND DEVELOPMENT OF A 3D PRINTED DRUG AND EQUIPMENT TRAY (SADET) TO FACILITATE UNASSISTED INTUBATION IN CRITICAL CARE SCENARIOS

Abstract

Background:

Unassisted endotracheal intubation in emergency or resource-limited environments places immense cognitive and operational demands on anesthesiologists, often causing delays or errors due to disorganized equipment and drug arrangements.

Objective:

To design, develop, and evaluate the Situational Airway Drug & Equipment Tray (SADET) — a low-cost, 3D-printed device to improve ergonomic layout, speed, and safety during unassisted intubation.

Study Design:

Prospective, simulation-based crossover usability study with iterative design and evaluation.

Sample Size:

Fifteen qualified anesthesiologists  participated. Each performed two runs with the standard setup and two with SADET (30 runs per setup).

Methods:

• Design Phase: Needs assessment (interviews with >10 anesthesiologists) to identify workflow barriers, design modelling and 3D printing.
• Evaluation Phase: Participants completed two simulated unassisted intubation runs with each setup, using standardized airway kits and drug vials.
• Metrics Recorded: Setup time, intubation time, drug/equipment retrieval time, drug identification errors, and satisfaction ratings.

Results:

SADET improved setup time by 64%, reduced drug/equipment retrieval times by 54%, shortened total intubation time by 39%, and eliminated all drug identification errors versus baseline. Satisfaction scores increased from 2.8/5 to 4.7/5.

Conclusion:

SADET significantly improved efficiency, safety, and workflow in simulated unassisted intubations. It is affordable, reproducible, and adaptable for various clinical environments.