Airway Simulator V2
Modular bronchoscopy rehearsal platform with printable anatomy and tactile feedback.
Build a realistic airway lab station using readily available hardware, printable components, and a modular control box that simulates bleeding, suction, and ventilation scenarios.
Download kit
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Complete STL Pack
Segmented airway, vascular tree, and modular base plates ready for 200 x 200 mm printers.
- Estimated print/build time: 38 hrs
- Estimated material cost: $22 filament
- Updated: 8/12/2024
Electronics Wiring Guide
Wiring diagram, firmware config, and laser-cut control panel layout.
- Estimated print/build time: —
- Estimated material cost: $45 components
- Updated: 7/2/2024
Control Box Firmware
Arduino firmware with presets for bleeding, secretions, and ventilation cues.
- Estimated print/build time: Upload in <5 min
- Estimated material cost: $0
- Updated: 6/18/2024
Build guide
Overview
The Airway Simulator emphasises modularity: swap different airway anatomies, connect to oxygen and suction, and trigger real-time responses via a compact control box. Assembly takes roughly a weekend with access to FDM printers and basic soldering tools.
- Provide tactile rehearsal for bronchoscopy and stent placement.
- Allow quick swap of airway cartridges for varying pathology.
- Support video capture and suction to mimic OR feedback.
Materials
Quantity
2 spools
Use higher temp PLA+ for durability.
Quantity
3 meters
Quantity
1
For bleeding/secretions simulation.
Quantity
1 set
Quantity
300 x 300 mm
Base padding.
Quantity
1 pack
Printing & Prep
Print the airway cartridges upright with supports and the base plates flat for rigidity. A 0.2 mm layer height and 20% gyroid infill balance strength and material use.
- Slice airway parts with tree supports and paint-on support blockers around the larynx to reduce cleanup.
- Print vascular overlays separately in flexible TPU for increased durability.
- Allow parts to cool fully before removing supports to prevent warping of long bronchial segments.
Assembly
Prepare airway cartridge
Wet-sand support scars and seal the airway lumen with a thin silicone coat to improve scope glide.
Install tubing manifold
Route silicone tubing through the anterior port, anchoring with M4 screws and compression gaskets.
Wire control box
Solder the pump, LEDs, and sensors to the relay shield as per the wiring guide, then upload firmware.
Final enclosure fit
Mount the airway cartridge, secure the removable cover, and perform a leak test with water.
Usage & maintenance
Run a calibration cycle before each session to prime pumps and verify suction strength.
Swap to the bleeding cassette to simulate hemoptysis control and gauging irrigation requirements.
Pair with the Mediastinal Lymph Node atlas to stage cases before hands-on rehearsal.
Maintenance
- Flush tubing with warm water after each use to prevent clogging.
- Inspect relay contacts quarterly and replace any discoloured components.
Additional resources
Editable Google Sheet with supplier links and bulk pricing.
90 minute build-along session recorded at the IP Lab.
Disclaimers
Note: This simulator is intended for educational use only and should not be used on patients.
Note: Always verify 3D print settings and perform post-processing before classroom use.
Downloads will route through /api/download/[fileId] once the M11 analytics backend is online. Until then, files are served directly.