The anatomical head support for the ICU is a silicone-based support that allows the patient's head to be accommodated in lateral decubitus in a comfortable and firm manner, facilitating intervention in intensive care units.

This project was developed to meet a need signaled by the Fiocruz physiotherapy team in the treatment of hospitalized patients with covid-19 who need to perform the prone position procedure.

Prone position: : https://www.youtube.com/watch?v=XV8j0E0dMNI&feature=youtu.be

One of the first lines of treatment for patients with moderate to severe cases is the prone position and this device is essential in the treatment of patients with covid19

The project was created for a pilot test for the treatment of prone to replace the improvised cushion that was being used in an emergency.

One of the first lines of treatment for patients with moderate to severe cases of covid-19 is the prone position and this device is essential in the procedure.

The project was created for a pilot test in the treatment of prone to replace the improvised cushion that was being used in an emergency. And overcome the difficulties pointed out by the medical team:

• Lack of supplier

• Inadequate available models

• Other more expensive models

Step 2: Virtual prototypes

From the models found on the market and the needs of use pointed out by the physiotherapy team, a product was redesigned in the Fuison 360, generating some virtual prototypes for a first validation. Two versions were chosen to be tested. From the models found on the market and the needs of use pointed out by the physiotherapy team, a product was redesigned in the Fuison 360, generating some virtual prototypes for a first validation. Two versions were chosen to be tested. From the models found on the market and the needs of use pointed out by the physiotherapy team, a product was redesigned in the Fuison 360, generating some virtual prototypes for a first validation. Two versions were chosen to be tested.From the models found on the market and the needs of use pointed out by the physiotherapy team, a product was redesigned in the Fuison 360, generating some virtual prototypes for a first validation. Two versions were chosen to be tested.

Step 3: Prototype 1

We chose one of the models selected by the team to make a quick prototype in order to validate the volume of the project. The 3D model was processed from the Slicer for fusion generating stackable cutting planes. Using the laser cutter we made this experimental version with MDF and EVA..  

Step 4: Feedback 

With feedback from the first prototype, we came to the conclusion of discarding one of the chosen models and applying adjustments to the second virtual model, which apparently would be more promising..

For the second experiment we decided to make a more reliable prototype using silicone that would be the final material for the project.

The first step was to print the entire piece on a 3D FDM printer and then make a mold from it..

As the part made in the 3D printer presents a roughness due to its manufacturing process, it was necessary to finish it with epox, sandpaper and prime to make the part very smooth.

We built a sealed mdf box to extract a mold from the finished piece. The mold was made with liquid silicone. To make the mold, 5 kg of liquid silicone were needed.

With the mode ready, we remove the printed part and put liquid silicone in the mold to manufacture the new silicone part.

Prototype 2 was sent for testing at the hospital. Some adjustment needs in height and in the chin area were detected.

And so we started the final version of the project.

1. After making the necessary adjustments to the virtual model, we follow the same steps as the second prototype:
2. 1. 3D printing
3. 2. Finishing
4. 3. Mold making
5. 4. Fabrication of the silicone part

Prototype 3 was sent to be tested in the hospital and it worked very well.

Its manufacture requires approximately 2 kg of liquid silicone and the curing time is 24 hours.

We hope that this project can help in the treatment of future patients..

3D Model

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Project documentation: https://fablab.casafirjan.com.br/#!/projects/apoio-anatomico-cirurgico-para-cabeca