3D printer saves ten Italian coronavirus patients' lives by producing a replacement valve for a broken ventilator in just a few hours after the hospital's supplier falls short

  • Chiari hospital found itself short of the spare ventilator parts on Friday March 13 
  • With the supplier unable to help in time, local tech experts came to the rescue
  • Local engineer Christian Fracassi transported his own 3D printer to the hospital 
  • He then designed and printed replacement valves for the intensive care machine
  • The original maker of the parts reportedly declined to share the valve specs 
  • Coronavirus symptoms: what are they and should you see a doctor?

A 3D printer saved ten coronavirus patients' lives by producing a replacement valve for a broken ventilator in just a few hours after the hospital's supplier fell short.

Ventilators — or respirators — provide patients with oxygen when they are unable to breathe on their own, such as can result in severe coronavirus cases.

Spare valves for the vital intensive care machine were running out on Friday at the Chiari hospital in the town of Iseo, in northern Italy's Lombardy region.

A collaboration between 3D printing experts and local business owners came to the rescue, however — rapidly fabricating the replacement parts.

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A 3D printer saved ten coronavirus patients' lives by producing a replacement valve for a broken ventilator in just a few hours after the hospital's supplier fell short. Pictured, engineer Christian Fracassi, left, and colleague seen here with the 3D printed valves

A 3D printer saved ten coronavirus patients' lives by producing a replacement valve for a broken ventilator in just a few hours after the hospital's supplier fell short. Pictured, engineer Christian Fracassi, left, and colleague seen here with the 3D printed valves

'As you know in northern Italy the COVID-19 emergency is very serious,' industrial engineer Marco Silvestri of the University of Parma told Fabbaloo.

To date, Italy — the country in Europe most severely impacted by coronavirus — has counted 24,747 individual cases and 1,809 deaths. 

'New resuscitation departments equipped with machinery to ventilate patients are being set up with great urgency,' Professor Silvestri added.

'Thanks to 3D printing, people are compensating for the lack of spare parts.'

'There are patent and validation issue in using these non-original spare parts, but when it is a matter of hours to avoid people dying, it's time to make exceptions.'

Doctors at the Chiari hospital, located near a region of Italy that has been particularly hard-hit by the coronavirus outbreak, raised the alarm on March 13 after it became clear their supplier would not be able to provide new ventilator valves in time.

They reached out to Nunzia Vallini — editor of the Giornale di Brescia, a local newspaper — who approached physicist and 3D printing expert Massimo Temporelli.

The duo began seeking someone local in possession of a 3D printer that could be taken to the hospital to reproduce the much-need spare valves for the ventilator.

Christian Fracassi, a local engineer and business owner, rose to the occasion, bringing his printer to the hospital and — within a matter of hours — succeeded in redesigning and printing a replacement part for the intensive care machine.

Ventilators — or respirators — provide patients with oxygen when they are unable to breathe on their own, such as can result in severe coronavirus cases. Spare valves for the vital intensive care machine were running out on Friday at the Chiari hospital in the town of Iseo, in northern Italy's Lombardy region. Pictured, some of the 3D printed replacement valves

Ventilators — or respirators — provide patients with oxygen when they are unable to breathe on their own, such as can result in severe coronavirus cases. Spare valves for the vital intensive care machine were running out on Friday at the Chiari hospital in the town of Iseo, in northern Italy's Lombardy region. Pictured, some of the 3D printed replacement valves

The initial replacement parts were made by so-called filament extrusion — in which a plastic wire is melted and deposited layer-by-layer to make up the desired object — by Mr Fracassi on site at the hospital.

Additional valves were later printed from the same template by the local manufacturing firm Lonati SpA, using a slightly different process in which a laser is used to melt and fuse a powder together to build up successive layers of an object.

According to the Italian newspaper La Stampa, the company that manufacturers the valves refused to supply Mr Fracassi and his associates with the specs for the original valve designs — and warned them off of trying to reproduce the part.

‘I have lawyers who are evaluating the matter,' Mr Fracassi told the news outlet TPI.

'I am not dealing with it personally because I prefer to devote myself to [the 3D designs].’ 

‘There were people in danger of life, and we acted. Period,' he added.

'We have no intention of profiting from this situation. We are not going to use the designs or product beyond the strict need that forced us to act.' 

The initial replacement parts were made by so-called filament extrusion — in which a plastic wire is melted and deposited layer-by-layer to make up the desired object — by Mr Fracassi on site at the hospital. Additional valves, pictured, were later printed from the same template by the local manufacturing firm Lonati SpA, using a slightly different process in which a laser is used to melt and fuse a powder together to build up successive layers of an object

The initial replacement parts were made by so-called filament extrusion — in which a plastic wire is melted and deposited layer-by-layer to make up the desired object — by Mr Fracassi on site at the hospital. Additional valves, pictured, were later printed from the same template by the local manufacturing firm Lonati SpA, using a slightly different process in which a laser is used to melt and fuse a powder together to build up successive layers of an object

Some have criticised the engineers for producing valves that have not passed the customary safety certifications before being used.

In response, Mr Temporelli told La Stampa that this was true, 'But when there's no time and people are risking their lives, you can't stop because of bureaucracy.'

It remains unclear, however, how the durable the stopgap parts are and whether they would be able to be sterilised and reused without being damaged.

According to Mr Temporelli, other medical facilities — including those located in Pescara, on Italy's eastern coast, and in Sassari, on Sardinia — have already been in contact looking for help addressing their valve shortages as well. 

Spare valves for the vital intensive care machine were running out on Friday at the Chiari hospital in the town of Iseo, in northern Italy's Lombardy region

Spare valves for the vital intensive care machine were running out on Friday at the Chiari hospital in the town of Iseo, in northern Italy's Lombardy region

WHAT DO WE KNOW ABOUT THE CORONAVIRUS?

What is the coronavirus? 

A coronavirus is a type of virus which can cause illness in animals and people. Viruses break into cells inside their host and use them to reproduce itself and disrupt the body's normal functions. Coronaviruses are named after the Latin word 'corona', which means crown, because they are encased by a spiked shell which resembles a royal crown.

The coronavirus from Wuhan is one which has never been seen before this outbreak. It has been named SARS-CoV-2 by the International Committee on Taxonomy of Viruses. The name stands for Severe Acute Respiratory Syndrome coronavirus 2.

Experts say the bug, which has killed around one in 50 patients since the outbreak began in December, is a 'sister' of the SARS illness which hit China in 2002, so has been named after it.

The disease that the virus causes has been named COVID-19, which stands for coronavirus disease 2019.

Dr Helena Maier, from the Pirbright Institute, said: 'Coronaviruses are a family of viruses that infect a wide range of different species including humans, cattle, pigs, chickens, dogs, cats and wild animals. 

'Until this new coronavirus was identified, there were only six different coronaviruses known to infect humans. Four of these cause a mild common cold-type illness, but since 2002 there has been the emergence of two new coronaviruses that can infect humans and result in more severe disease (Severe acute respiratory syndrome (SARS) and Middle East respiratory syndrome (MERS) coronaviruses). 

'Coronaviruses are known to be able to occasionally jump from one species to another and that is what happened in the case of SARS, MERS and the new coronavirus. The animal origin of the new coronavirus is not yet known.' 

The first human cases were publicly reported from the Chinese city of Wuhan, where approximately 11million people live, after medics first started publicly reporting infections on December 31.

By January 8, 59 suspected cases had been reported and seven people were in critical condition. Tests were developed for the new virus and recorded cases started to surge.

The first person died that week and, by January 16, two were dead and 41 cases were confirmed. The next day, scientists predicted that 1,700 people had become infected, possibly up to 7,000. 

Where does the virus come from?

According to scientists, the virus almost certainly came from bats. Coronaviruses in general tend to originate in animals – the similar SARS and MERS viruses are believed to have originated in civet cats and camels, respectively.

The first cases of COVID-19 came from people visiting or working in a live animal market in Wuhan, which has since been closed down for investigation.

Although the market is officially a seafood market, other dead and living animals were being sold there, including wolf cubs, salamanders, snakes, peacocks, porcupines and camel meat. 

A study by the Wuhan Institute of Virology, published in February 2020 in the scientific journal Nature, found that the genetic make-up virus samples found in patients in China is 96 per cent identical to a coronavirus they found in bats.

However, there were not many bats at the market so scientists say it was likely there was an animal which acted as a middle-man, contracting it from a bat before then transmitting it to a human. It has not yet been confirmed what type of animal this was.

Dr Michael Skinner, a virologist at Imperial College London, was not involved with the research but said: 'The discovery definitely places the origin of nCoV in bats in China.

'We still do not know whether another species served as an intermediate host to amplify the virus, and possibly even to bring it to the market, nor what species that host might have been.'  

So far the fatalities are quite low. Why are health experts so worried about it? 

Experts say the international community is concerned about the virus because so little is known about it and it appears to be spreading quickly.

It is similar to SARS, which infected 8,000 people and killed nearly 800 in an outbreak in Asia in 2003, in that it is a type of coronavirus which infects humans' lungs. It is less deadly than SARS, however, which killed around one in 10 people, compared to approximately one in 50 for COVID-19.

Another reason for concern is that nobody has any immunity to the virus because they've never encountered it before. This means it may be able to cause more damage than viruses we come across often, like the flu or common cold.

Speaking at a briefing in January, Oxford University professor, Dr Peter Horby, said: 'Novel viruses can spread much faster through the population than viruses which circulate all the time because we have no immunity to them.

'Most seasonal flu viruses have a case fatality rate of less than one in 1,000 people. Here we're talking about a virus where we don't understand fully the severity spectrum but it's possible the case fatality rate could be as high as two per cent.'

If the death rate is truly two per cent, that means two out of every 100 patients who get it will die. 

'My feeling is it's lower,' Dr Horby added. 'We're probably missing this iceberg of milder cases. But that's the current circumstance we're in.

'Two per cent case fatality rate is comparable to the Spanish Flu pandemic in 1918 so it is a significant concern globally.'

How does the virus spread?

The illness can spread between people just through coughs and sneezes, making it an extremely contagious infection. And it may also spread even before someone has symptoms.

It is believed to travel in the saliva and even through water in the eyes, therefore close contact, kissing, and sharing cutlery or utensils are all risky. It can also live on surfaces, such as plastic and steel, for up to 72 hours, meaning people can catch it by touching contaminated surfaces.

Originally, people were thought to be catching it from a live animal market in Wuhan city. But cases soon began to emerge in people who had never been there, which forced medics to realise it was spreading from person to person. 

What does the virus do to you? What are the symptoms?

Once someone has caught the COVID-19 virus it may take between two and 14 days, or even longer, for them to show any symptoms – but they may still be contagious during this time.

If and when they do become ill, typical signs include a runny nose, a cough, sore throat and a fever (high temperature). The vast majority of patients will recover from these without any issues, and many will need no medical help at all.

In a small group of patients, who seem mainly to be the elderly or those with long-term illnesses, it can lead to pneumonia. Pneumonia is an infection in which the insides of the lungs swell up and fill with fluid. It makes it increasingly difficult to breathe and, if left untreated, can be fatal and suffocate people.

Figures are showing that young children do not seem to be particularly badly affected by the virus, which they say is peculiar considering their susceptibility to flu, but it is not clear why. 

What have genetic tests revealed about the virus? 

Scientists in China have recorded the genetic sequences of around 19 strains of the virus and released them to experts working around the world. 

This allows others to study them, develop tests and potentially look into treating the illness they cause.   

Examinations have revealed the coronavirus did not change much – changing is known as mutating – much during the early stages of its spread.

However, the director-general of China's Center for Disease Control and Prevention, Gao Fu, said the virus was mutating and adapting as it spread through people.

This means efforts to study the virus and to potentially control it may be made extra difficult because the virus might look different every time scientists analyse it.   

More study may be able to reveal whether the virus first infected a small number of people then change and spread from them, or whether there were various versions of the virus coming from animals which have developed separately.

How dangerous is the virus?  

The virus has a death rate of around two per cent. This is a similar death rate to the Spanish Flu outbreak which, in 1918, went on to kill around 50million people.

Experts have been conflicted since the beginning of the outbreak about whether the true number of people who are infected is significantly higher than the official numbers of recorded cases. Some people are expected to have such mild symptoms that they never even realise they are ill unless they're tested, so only the more serious cases get discovered, making the death toll seem higher than it really is.

However, an investigation into government surveillance in China said it had found no reason to believe this was true.

Dr Bruce Aylward, a World Health Organization official who went on a mission to China, said there was no evidence that figures were only showing the tip of the iceberg, and said recording appeared to be accurate, Stat News reported.

Can the virus be cured? 

The COVID-19 virus cannot be cured and it is proving difficult to contain.

Antibiotics do not work against viruses, so they are out of the question. Antiviral drugs can work, but the process of understanding a virus then developing and producing drugs to treat it would take years and huge amounts of money.

No vaccine exists for the coronavirus yet and it's not likely one will be developed in time to be of any use in this outbreak, for similar reasons to the above.

The National Institutes of Health in the US, and Baylor University in Waco, Texas, say they are working on a vaccine based on what they know about coronaviruses in general, using information from the SARS outbreak. But this may take a year or more to develop, according to Pharmaceutical Technology.

Currently, governments and health authorities are working to contain the virus and to care for patients who are sick and stop them infecting other people.

People who catch the illness are being quarantined in hospitals, where their symptoms can be treated and they will be away from the uninfected public.

And airports around the world are putting in place screening measures such as having doctors on-site, taking people's temperatures to check for fevers and using thermal screening to spot those who might be ill (infection causes a raised temperature).

However, it can take weeks for symptoms to appear, so there is only a small likelihood that patients will be spotted up in an airport.

Is this outbreak an epidemic or a pandemic?   

The outbreak was declared a pandemic on March 11. A pandemic is defined by the World Health Organization as the 'worldwide spread of a new disease'. 

Previously, the UN agency said most cases outside of Hubei had been 'spillover' from the epicentre, so the disease wasn't actually spreading actively around the world.

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