This work contributes to the use of design and digital manufacturing tools for the rapid development of respiratory therapy devices. Leveraging the flexibility of Industry 4.0 technologies, the team developed an automated, decentralized manufacturing process. This methodology was applied in the design and production of a batch of high-flow humidifiers, essential for treating patients with respiratory diseases. Using CAD software, the exact geometry of all components was modeled, allowing a detailed analysis of component integration and establishing dimensional tolerances for assemblies. This resulted in a set of geometric information files that are transferable to other design phases and serve as a basis for future redesigns. The same approach was applied to CAM-generated fabrication files, optimizing parameters for time and quality in mass production.

Thanks to digital manufacturing tools, the precise time and material requirements for production were predicted, enabling the flexible and continuous production of two humidifiers per day at the Fab Lab – UTP. Additionally, an air-oxygen mixing chamber was designed using the Venturi effect, commonly employed in medical gas mixing. Computational fluid dynamics (CFD) were used to ensure proper fluid design. The range of flow and FIO2 parameters provided by the humidifier was characterized, deeming the device suitable for respiratory therapy based on the latest research.