When a person suffers a blockage in their upper airway, they require a surgical procedure known as a tracheostomy that creates an incision into their windpipe, enabling them to breathe. A tube is then inserted to keep the airway open. That tube is secured with a faceplate, which is held to the neck with a strap.
Unfortunately, the available faceplates and straps cause problems in the weeks following the surgery; The faceplate directly contacts the incision which slows healing and prevents proper monitoring and dressing, and the strap is often over-tensioned, which causes sores to develop. These problems are exacerbated for pediatric patients. As such, my Mechanical Engineering Capstone project is to redesign the faceplate and implement tension monitoring in the strap to alleviate these issues for children.
This design will prevent under and over-tensioning by using two elastic threads, secured at the same points along the length of the strap, but with different amounts of slack. As the strap stretches, the low slack thread will contact the strap first, indicating that the lower bound for tension has been achieved. If over-tensioning occurs, the high slack thread will do the same, indicating that the caregiver should loosen the strap. This design visualizes tension at many discrete points around the neck, helping caregivers prevent pressure hotspots.
This is an early design for the faceplate that creates a gap between itself and the incision to prevent mechanical disruption and ease wound monitoring and dressing application. Soon, TPU 3D prints will be used to qualitatively evaluate and iteratively improve this model prior to in-depth testing. A prototype mold for the final design will be ordered by March 2023.