Design optimization and clinical prospects of a novel portable split-type negative pressure thoracic drainage device

To overcome the clinical limitations of traditional wall-mounted negative pressure drainage devices, which restrict early postoperative mobility and may delay enhanced recovery, this study aimed to optimize a self-developed portable thoracic drainage system through iterative design improvements.

A novel second-generation portable negative pressure thoracic drainage device was developed based on a first-generation integrated design. The second-generation device employs a split-type architecture, wherein the negative pressure pump, power module, and optimized noise reduction system are integrated into an independent portable host via 3D printing technology. A flexible attachment method using double-sided adhesive tape and 3M hook-and-loop fasteners allows the host to be securely yet removably attached to the side of a standard three-chamber drainage bottle. The design prioritizes operational simplicity and clinical workflow compatibility.

The optimized device features a compact host measuring 139.6 × 95.6 × 35 mm and weighing about 400 g. The maximum negative pressure intensity main depends on the height of the water column in the three-chamber closed drainage bottle (close to 20 cm H₂O), host unit noise below 55 dB at a 3 L/min flow rate, and a battery life of 6-10 h. The estimated manufacturing cost is about 500 Chinese Yuan (~70 USD) per device unit, with a single-use consumable cost (drainage bottle) of about 45 Chinese Yuan (~6.3 USD).

This study proposed the concept of a novel type of portable negative pressure thoracic drainage device and designed and manufactured a sample. In the next step, we will continue to improve this novel device and plan to apply it in clinical practice.