Design, Development, and Mechanical Stress Testing of a 3D-printed, Low-Cost, Modular, Smartphone-Based Video Laryngoscope

Background Videolaryngoscopes provide many key advantages over direct laryngoscopy, including an improved view of the glottis and a greater first-attempt success rate. However, videolaryngoscopy systems are costly and not as accessible in lower-income countries and hospital systems. 3D printing has revolutionized medical tools by allowing for rapid prototyping and low-cost devices. In particular, 3D-printed videolaryngoscopes have already demonstrated their clinical viability as many anesthesia providers have implemented these devices on their medical missions around the world. Methods The GHAVL was designed with a computer-aided design software and 3D-printed from polylactic acid filament. A low-cost device was developed with the goal of containing excess wires and enabling single-operator use. Finite element analysis was conducted to determine the mechanical performance under incremental loads at the tip of the blade. Results The GHAVL consists of two main components: the blade/handle unit and the phone mount. The blade/handle unit was designed with a hollow handle to contain excess wires, and the two components connect via a snap-twist mechanism for rapid, reliable joining. Finite element analysis demonstrated the GHAVL blade tip displacements of 1.5mm, 3mm, 4.5mm, and 9mm under a load of 50N, 100N, 150N, and 300N, respectively. Conclusion The GHAVL is a modular system that integrates with an industrial endoscope and smartphone to create a low-cost, single-operator videolaryngoscope. Stress testing suggests the GHAVL’s structural integrity and ability to withstand forces of up to 150N with minimal blade deformation. The GHAVL demonstrates great promise, but it still requires extensive testing to determine its clinical applicability.