The ABC Intubation Enclosure

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Atlanta Beats Covid (ABC) is teaming up with some top-notch healthcare workers at Emory University Hospital to develop a game-changing intubation enclosure. Our focus has been on creating an exceptional product that meets the following key requirements: portability, ease of storage, ease of sterilization and prevention of contamination, and low-cost manufacturing. To achieve these goals, we're introducing a flat-pack structure made up of four polycarbonate panels, eight plastic snap-fit connectors, and two plastic portholes for attaching disposable sterile sleeves. We've chosen polycarbonate (nominal 4.5mm) due to its resistance to common cleaning fluids, its stiffness, and widespread availability. At approximately 23 inches square, the panels can be cut from commonly found 2x2 foot sheets or nested onto a 4x4 foot sheet. We recommend cutting with a waterjet or CNC router, but it's also possible to cut them manually in theory (laser cutting polycarbonate at this thickness is not feasible). The snap-fit connectors and portholes can be 3D printed or molded, with mold CAD coming soon. For 3D printing, we recommend using ABS with acetone smoothing or another filament with good mechanical properties. While PLA works surprisingly well, we've included print settings that work well in an image for your reference (print on the end to ensure layer lines are not along a snap axis). The enclosure also features hand-holds and slots for accommodating tubes already present when assembled. Our estimated all-up cost (excluding tax, without volume discounts) breaks down as follows: half of a 4x8 foot sheet of .177 inch polycarb costs $73, while roughly 260 grams of 3D printer filament costs $6, totaling $80. Note that this design or variants similar to it are free for use. We encourage you to share it widely and would love to hear your feedback or remixes.