CAPR Replacement Parts

Collaborators: Stanford Procurement Operations

Controlled Air Purifying Respirator (CAPR) systems were widely used during the COVID-19 pandemic to provide respiratory protection for healthcare workers. Several small plastic components were prone to breaking, and replacement parts became difficult to obtain quickly and at a reasonable cost during periods of high demand.

To address this shortage, Stanford Procurement Operations and Strategy provided the 3DQ Lab with the components needing replacement and a CAPR unit for reference. Four different parts were identified as priorities for replacement so that existing systems could be repaired rather than taken out of service.

Figure A: One of four replacement CAPR components designed by the 3DQ Lab, shown next to its corresponding location on the respirator assembly.

Figure B: 3D printed replacement component installed on the CAPR unit, demonstrating fit and compatibility with the original system.

Figure C: One of the print trays containing multiple replacement CAPR components, demonstrating the high volume of parts produced.

Using measurement tools and CAD design, the 3DQ Lab reverse engineered each of the four replacement components and created printable versions matched to the original parts. Over the span of several months, the lab printed, cleaned, and delivered hundreds of parts to replenish Stanford Health Care’s inventory and support continued clinical operations.

This project illustrates how in-house design and manufacturing can respond rapidly when commercial supply chains are disrupted. By reproducing small but essential components, the 3DQ Lab helped keep critical respiratory protection equipment in service during a period of extraordinary demand.

Custom Foot Orthotic DesignRib Stabilization Model