Clinical Center Doctors Testing 3D-Printed Miniature Ventilator
Posted on by James K. Gilman, MD, NIH Clinical Center
Here at the NIH Clinical Center, we are proud to be considered a world-renowned research hospital that provides hope through pioneering clinical research to improve human health. But what you may not know is that our doctors are constantly partnering with public and private sectors to come up with innovative technologies that will help to advance health outcomes.
I’m excited to bring to you a story that is perfect example of the ingenuity of our NIH doctors working with global strategic partners to create potentially life-saving technologies. This story begins during the COVID-19 pandemic with the global shortage of ventilators to help patients breathe. Hospitals had a profound need for inexpensive, easy-to-use, rapidly mass-produced resuscitation devices that could be quickly distributed in areas of critical need.
Through strategic partnerships, our Clinical Center doctors learned about and joined an international group of engineers, physicians, respiratory therapists, and patient advocates using their engineering skills to create a ventilator that was functional, affordable, and intuitive. After several iterations and bench testing, they devised a user-friendly ventilator.
Then, with the assistance of 3D-printing technology, they improved the original design and did something pretty incredible: the team created the smallest single-patient ventilator seen to date. The device is just 2.4 centimeters (about 1 inch) in diameter with a length of 7.4 centimeters (about 3 inches).
A typical ventilator in a hospital obviously is much larger and has a bellows system. It fills with oxygen and then forces it into the lungs followed by the patient passively exhaling. These systems have multiple moving parts, valves, hoses, and electronic or mechanical controls to manage all aspects of the oxygen flow into the lungs.
But our miniature, 3D-printed ventilator is single use, disposable, and has no moving parts. It’s based on principles of fluidics to ventilate patients by automatically oscillating between forced inspiration and assisted expiration as airway pressure changes. It requires only a continuous supply of pressurized oxygen.
The possibilities of this 3D-printed miniature ventilator are broad. The ventilators could be easily used in emergency transport, potentially treating battlefield casualties or responding to disasters and mass casualty events like earthquakes.
While refining a concept is important, the key is converting it to actual use, which our doctors are doing admirably in their preclinical and clinical studies. NIH’s William Pritchard, Andrew Mannes, Brad Wood, John Karanian, Ivane Bakhutashvili, Matthew Starost, David Eckstein, and medical student Sheridan Reed studied and have already tested the ventilators in swine with acute lung injury, a common severe outcome in a number of respiratory threats including COVID-19.
In the study, the doctors tested three versions of the device built to correspond to mild, moderate, and severe lung injury. The respirators provided adequate support for moderate and mild lung injuries, and the doctors recall how amazing it was initially to witness a 190-pound swine ventilated by this miniature ventilator.
The doctors believe that the 3D-printed miniature ventilator is a potential “game changer” from start to finish since it is lifesaving, small, simple to use, can be easily and inexpensively printed and stored, and does not require additional maintenance. They recently published their preclinical trial results in the journal Science Translational Medicine .
The NIH team is preparing to initiate first-in-human trials here at the Clinical Center in the coming months. Perhaps, in the not-too-distant future, a device designed to help people breathe could fit into your pocket next to your phone and keys.
 In-line miniature 3D-printed pressure-cycled ventilator maintains respiratory homeostasis in swine with induced acute pulmonary injury. Pritchard WF, Karanian JW, Jung C, Bakhutashvili I, Reed SL, Starost MF, Froelke BR, Barnes TR, Stevenson D, Mendoza A, Eckstein DJ, Wood BJ, Walsh BK, Mannes AJ. Sci Transl Med. 2022 Oct 12;14(666):eabm8351.
Clinical Center (NIH)
Andrew Mannes (Clinical Center)
Bradford Wood (Clinical Center)
David Eckstein (Clinical Center)
Note: Dr. Lawrence Tabak, who performs the duties of the NIH Director, has asked the heads of NIH’s Institutes and Centers (ICs) to contribute occasional guest posts to the blog to highlight some of the interesting science that they support and conduct. This is the 21st in the series of NIH IC guest posts that will run until a new permanent NIH director is in place.
Learning from History: Fauci Donates Model to Smithsonian’s COVID-19 Collection
Posted on by Dr. Francis Collins
Not too long after the global coronavirus disease 2019 (COVID-19) pandemic reached the United States, museum curators began collecting material to document the history of this devastating public health crisis and our nation’s response to it. To help tell this story, the Smithsonian Institution’s National Museum of American History recently scored a donation from my friend and colleague Dr. Anthony Fauci, Director of NIH’s National Institute of Allergy and Infectious Diseases.
Widely recognized for serving as a clear voice for science throughout the pandemic, Fauci gave the museum his much-used model of SARS-CoV-2, which is the coronavirus that causes COVID-19. This model, which is based on work conducted by NIH-supported electron microscopists and structural biologists, was 3D printed right here at NIH. By the way, I’m lucky enough to have one too.
Both of these models have “met” an amazing array of people—from presidents to congresspeople to journalists to average citizens—as part of our efforts to help folks understand SARS-CoV-2 and the crucial role of its surface spike proteins. As shown in this brief video, Fauci raised his model one last time and then, ever the public ambassador for science, turned his virtual donation into a memorable teaching moment. I recommend you take a minute or two to watch it.
The donation took place during a virtual ceremony in which the National Museum of American History awarded Fauci its prestigious Great Americans Medal. He received the award for his lifetime contributions to the nation’s ideals and for making a lasting impact on public health via his many philanthropic and humanitarian efforts. Fauci joined an impressive list of luminaries in receiving this honor, including former Secretaries of State Madeleine Albright and General Colin Powell; journalist Tom Brokaw; baseball great Cal Ripken Jr.; tennis star Billie Jean King; and musician Paul Simon. It’s a well-deserved honor for a physician-scientist who’s advised seven presidents on a range of domestic and global health issues, from HIV/AIDS to Ebola to COVID-19.
With Fauci’s model now enshrined as an official piece of U.S. history, the Smithsonian and other museums around the world are stepping up their efforts to gather additional artifacts related to COVID-19 and to chronicle its impacts on the health and economy of our nation. Hopefully, future generations will learn from this history so that humankind is not doomed to repeat it.
It is interesting to note that the National Museum of American History’s collection contains few artifacts from another tragic chapter in our nation’s past: the 1918 Influenza Pandemic. One reason this pandemic went largely undocumented is that, like so many of their fellow citizens, curators chose to overlook its devastating impacts and instead turn toward the future.
Today, museum staffers across the country and around the world are stepping up to the challenge of documenting COVID-19’s history with great creativity, collecting all variety of masks, test kits, vaccine vials, and even a few ventilators. At the NIH’s main campus in Bethesda, MD, the Office of NIH History and Stetten Museum is busy preparing a small exhibit of scientific and clinical artifacts that could open as early as the summer of 2021. The museum is also collecting oral histories as part of its “Behind the Mask” project. So far, more than 50 interviews have been conducted with NIH staff, including a scientist who’s helping the hard-hit Navajo Nation during the pandemic; a Clinical Center nurse who’s treating patients with COVID-19, and a mental health professional who’s had to change expectations since the outbreak.
The pandemic isn’t over yet. All of us need to do our part by getting vaccinated against COVID-19 and taking other precautions to prevent the virus’s deadly spread. But won’t it great when—hopefully, one day soon—we can relegate this terrible pandemic to the museums and the history books!
COVID-19 Research (NIH)
Video: National Museum of American History Presents The Great Americans Medal to Anthony S. Fauci (Smithsonian Institution, Washington, D.C.)
National Museum of American History (Smithsonian)
The Office of NIH History and Stetten Museum (NIH)
A Novel, 3D-Printed Virus
Posted on by Dr. Francis Collins
In the blog post “3D Printing the Novel Coronavirus,” I mentioned receiving my very own 3D-printed model of the novel coronavirus SARS-CoV-2, the cause of COVD-19. I shared this impressive model, created by the NIH 3D Print Exchange, with viewers during our third virtual NIH Town Hall meeting. The one-hour meeting was held on May 21, 2020 for employees, contractors, fellows, and trainees now sheltering at home to discuss the multi-phased return to the NIH workplace that will begin in June. Credit: NIH
3D Printing the Novel Coronavirus
Posted on by Dr. Francis Collins
The coronavirus disease 2019 (COVID-19) pandemic has truly been an all-hands-on-deck moment for the nation. Among the responders are many with NIH affiliations, who are lending their expertise to deploy new and emerging technologies to address myriad research challenges. That’s certainly the case for the dedicated team from the National Institute of Allergy and Infectious Diseases (NIAID) at the NIH 3D Print Exchange (3DPX), Rockville, MD.
A remarkable example of the team’s work is this 3D-printed physical model of SARS-CoV-2, the novel coronavirus that causes COVID-19. This model shows the viral surface (blue) and the spike proteins studded proportionally to the right size and shape. These proteins are essential for SARS-CoV-2 to attach to human cells and infect them. Here, the spike proteins are represented in their open, active form (orange) that’s capable of attaching to a human cell, as well as in their closed, inactive form (red).
The model is about 5 inches in diameter. It takes more than 5 hours to print using an “ink” of thin layers of a gypsum plaster-based powder fused with a colored binder solution. When completed, the plaster model is coated in epoxy for strength and a glossy, ceramic-like finish. For these models, NIAID uses commercial-grade, full-color 3D printers. However, the same 3D files can be used in any type of 3D printer, including “desktop” models available on the consumer market.
Darrell Hurt and Meghan McCarthy lead the 3DPX team. Kristen Browne, Phil Cruz, and Victor Starr Kramer, the team members who helped to produce this remarkable model, created it as part of a collaboration with the imaging team at NIAID’s Rocky Mountain Laboratories (RML), Hamilton, MT.
The RML’s Electron Microscopy Unit captured the microscopic 3D images of the virus, which was cultured from one of the first COVID-19 patients in the country. The unit handed off these and other data to its in-house visual specialist to convert into a preliminary 3D model. The model was then forwarded to the 3DPX team in Maryland to colorize and optimize in preparation for 3D printing.
This model is especially unique because it’s based exclusively on SARS-CoV-2 data. For example, the model is assembled from data showing that the virus is frequently oval, not perfectly round. The spike proteins also aren’t evenly spaced, but pop up more randomly from the surface. Another nice feature of 3D printing is the models can be constantly updated to incorporate the latest structural discoveries.
That’s why 3D models are such an excellent teaching tools to share among scientists and the public. Folks can hold the plaster virus and closely examine its structure. In fact, the team recently printed out a model and delivered it to me for exactly this educational purpose.
In addition to this complete model, the researchers also are populating the online 3D print exchange with atomic-level structures of the various SARS-CoV-2 proteins that have been deposited by researchers around the world into protein and electron microscopy databanks. The number of these structures and plans currently stands at well over 100—and counting.
As impressive as this modeling work is, 3DPX has found yet another essential way to aid in the COVID-19 fight. In March, the Food and Drug Administration (FDA) announced a public-private partnership with the NIH 3D Print Exchange, Department of Veterans Affairs (VA) Innovation Ecosystem, and the non-profit America Makes, Youngstown, OH . The partnership will develop a curated collection of designs for 3D-printable personal protective equipment (PPE), as well as other necessary medical devices that are in short supply due to the COVID-19 pandemic.
You can explore the partnership’s growing collection of COVID-19-related medical supplies online. And, if you happen to have a 3D printer handy, you could even try making them for yourself.
 FDA Efforts to Connect Manufacturers and Health Care Entities: The FDA, Department of Veterans Affairs, National Institutes of Health, and America Makes Form a COVID-19 response Public-Private Partnership (Food and Drug Administration)
Coronavirus (COVID-19) (NIH)
NIH 3D Print Exchange (National Institute of Allergy and Infectious Diseases/NIH, Rockville, MD)
Rocky Mountain Laboratories (NIAID/NIH, Hamilton, MT)
Department of Veterans Affairs (VA) Innovation Ecosystem (Washington, D.C.)
America Makes (Youngstown, OH)
NIH Support: National Institute of Allergy and Infectious Diseases
3D Printing a Human Heart Valve
Posted on by Dr. Francis Collins
It is now possible to pull up the design of a guitar on a computer screen and print out its parts on a 3D printer equipped with special metal or plastic “inks.” The same technological ingenuity is also now being applied with bioinks—printable gels containing supportive biomaterials and/or cells—to print out tissue, bone, blood vessels, and, even perhaps one day, viable organs.
While there’s a long way to go until then, a team of researchers has reached an important milestone in bioprinting collagen and other extracellular matrix proteins that undergird every tissue and organ in the body. The researchers have become so adept at it that they now can print biomaterials that mimic the structural, mechanical, and biological properties of real human tissues.
Take a look at the video. It shows a life-size human heart valve that’s been printed with their improved collagen bioink. As fluid passes through the aortic valve in a lab test, its three leaf-like flaps open and close like the real thing. All the while, the soft, flexible valve withstands the intense fluid pressure, which mimics that of blood flowing in and out of a beating heart.
The researchers, led by NIH grantee Adam Feinberg, Carnegie Mellon University, Pittsburgh, PA, did it with their latest version of a 3D bioprinting technique featured on the blog a few years ago. It’s called: Freeform Reversible Embedding of Suspended Hydrogels v.2.0. Or, just FRESH v2.0.
The FRESH system uses a bioink that consists of collagen (or other soft biomaterials) embedded in a thick slurry of gelatin microparticles and water. While a number of technical improvements have been made to FRESH v. 2.0, the big one was getting better at bioprinting collagen.
The secret is to dissolve the collagen bioink in an acid solution. When extruded into a neutral support bath, the change in pH drives the rapid assembly of collagen. The ability to extrude miniscule amounts and move the needle anywhere in 3D space enables them to produce amazingly complex, high-resolution structures, layer by layer. The porous microstructure of the printed collagen also helps for incorporating human cells. When printing is complete, the support bath easily melts away by heating to body temperature.
As described in Science, in addition to the working heart valve, the researchers have printed a small model of a heart ventricle. By combining collagen with cardiac muscle cells, they found they could actually control the organization of muscle tissue within the model heart chamber. The 3D-printed ventricles also showed synchronized muscle contractions, just like you’d expect in a living, beating human heart!
That’s not all. Using MRI images of an adult human heart as a template, the researchers created a complete organ structure including internal valves, large veins, and arteries. Based on the vessels they could see in the MRI, they printed even tinier microvessels and showed that the structure could support blood-like fluid flow.
While the researchers have focused the potential of FRESH v.2.0 printing on a human heart, in principle the technology could be used for many other organ systems. But there are still many challenges to overcome. A major one is the need to generate and incorporate billions of human cells, as would be needed to produce a transplantable human heart or other organ.
Feinberg reports more immediate applications of the technology on the horizon, however. His team is working to apply FRESH v.2.0 for producing child-sized replacement tracheas and precisely printed scaffolds for healing wounded muscle tissue.
Meanwhile, the Feinberg lab generously shares its designs with the scientific community via the NIH 3D Print Exchange. This innovative program is helping to bring more 3D scientific models online and advance the field of bioprinting. So we can expect to read about many more exciting milestones like this one from the Feinberg lab.
 3D bioprinting of collagen to rebuild components of the human heart. Lee A, Hudson AR, Shiwarski DJ, Tashman JW, Hinton TJ, Yerneni S, Bliley JM, Campbell PG, Feinberg AW. Science. 2019 Aug 2;365(6452):482-487.
Tissue Engineering and Regenerative Medicine (National Institute of Biomedical Imaging and Bioengineering/NIH)
Regenerative Biomaterials and Therapeutics Group (Carnegie Mellon University, Pittsburgh, PA)
FluidForm (Acton, MA)
3D Bioprinting Open Source Workshops (Carnegie Mellon)
Video: Adam Feinberg on Tissue Engineering to Treat Human Disease (YouTube)
NIH Support: National Heart, Lung, and Blood Institute; Eunice Kennedy Shriver National Institute of Child Health and Human Development; Common Fund