Life-Saving Neonatal Airway Stabilization System
Define
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Every year, thousands of premature and critically ill infants face a hidden mechanical challenge: keeping their endotracheal tube (ETT) secure. Nearly 98% of premature babies require intubation, yet in 40% of cases, the tube dislodges with life-threatening consequences.
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ETTs must stay within ±0.5 cm for effective ventilation. Current methods using adhesive tape and plastic supports are unreliable, leading to frequent, risky adjustments.
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Consequences of today’s system:
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Patient instability → Sedation during adjustments disrupts blood pressure & heart rate
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Life-threatening errors → Even small missteps or movement can cause airway loss
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Inefficiency & frustration → ~33% of adjustments fail, requiring repeat sedation, re-taping, and X-rays
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The “ETT Shuffle” in one 24-bed pediatric ICU:
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~500 extra chest X-rays/year → $500,000
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Extra physician/therapist time → $100,000
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Additional sedatives → $80,000
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Unplanned extubations → Accreditation & medicolegal risk
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Pediatric surgeons at UT Dell Medical asked me to rethink this mechanically: create a solution that keeps ETTs secure, reduces dislodgement, and protects the most vulnerable patients.
Goal
Lead the design and prototyping of a novel endotracheal tube holder that balances engineering innovation with clinical realities. The solution needed to be:
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Clinically safe: Fully compatible with fragile neonatal patients.
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Manufacturable: Feasible using medical-grade materials and processes.
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Practical and adoptable: Intuitive and acceptable to surgeons, respiratory therapists, and ICU staff.
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Regulatory and business viable: Meeting medical standards while supporting hospital and commercial adoption.
The mission: engineer a solution that keeps lifelines secure, reduces risk, and improves both patient and clinician experience.
Approach
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I led the design and prototyping process, tackling the challenge from mechanical, clinical, and business perspectives. The approach combined iterative engineering, human-centered design, and rigorous testing
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User-Centered Research: Collaborated closely with neonatal surgeons, respiratory therapists, and ICU staff to understand real-world workflows, pain points, and constraints.
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Concept Ideation: Explored multiple mechanical concepts for secure, adjustable tube fixation.
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Prototype Development: Rapidly iterated designs using 3D printing and medical-grade materials, balancing durability, safety, and ease of use.
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Double Locking Spring Mechanism: Developed a precise double-locking spring system that allows millimeter-scale adjustments of tube position without risk of accidental movement, minimizing the need for repeated sedation or X-rays. Shown above, this mechanical system was later patented.
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Validation and Refinement: Tested prototypes in simulated ICU conditions, refining ergonomics, reliability, and clinical workflow integration.
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Business Model & Valuation: Designed a commercially viable strategy for adoption and scaling, culminating in a $7 million valuation for the solution.
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The result was a mechanically elegant, clinically practical, and commercially viable solution that improved patient safety, staff efficiency, and institutional value.
Impact
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75% reduction in tube dislodgement during validation testing, directly improving patient safety.
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Strong endorsement from pediatric surgeons and ICU clinicians, validating clinical practicality.
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$7M projected business valuation, demonstrating both commercial and medical potential.
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Cross-disciplinary execution: Successfully integrated medical feedback, mechanical design, and business strategy into a life-saving innovation.
Key Takeaways
Demonstrates the ability to tackle life-critical engineering challenges at the edge of possibility, translating urgent, real-world problems into innovative, reliable, and deployable solutions where failure is not an option and impact is immediate.