SafeAmpCase: design and optimization of a 3D-printed solution for protecting fragile life-saving drug ampoules

Abstract The SafeAmpCase is an innovative 3D-printed solution developed to address critical challenges in transporting and storing fragile glass drug ampoules during emergencies. This study employs a multidisciplinary approach—integrating biomedical engineering, advanced materials science, and emergency medicine expertise—to develop a compact, durable, and user-friendly ampoule case. A key innovation lies in the strategic selection of thermoplastic polyurethane (TPU) as the material, leveraging its superior impact resistance, flexibility, and noise-damping characteristics to ensure reliability under performance in demanding real-world conditions. To optimize the 3D printing process, key parameters, including printing temperature (220–250 °C), volumetric flow rate (3–20 mm 3 /s), retraction speed (30–90 mm/s), and retraction length (0.4–1.2 mm), were systematically adjusted using calibration models. The final optimized parameters (245 °C, 7 mm 3 /s, 90 mm/s, and 1.2 mm) reduced production time by 43% while preserving structural integrity. American Society for Testing and Materials (ASTM) international standard drop tests confirmed the case’s exceptional impact resistance, demonstrating a 90% reduction in ampoule breakage compared to polylactic acid plus. Further refinements, guided by feedback from 25 emergency professionals, resulted in medication-specific color coding and an enhanced locking mechanism for usability in high-pressure situations. The final SafeAmpCase model withstood 18 consecutive drop trials without ampoule breakage, confirming its robustness in field conditions. This research underscores the transformative potential of additive manufacturing in developing customized, high-performance solutions for critical healthcare applications, setting a new benchmark for biomedical device design and rapid prototyping.