Introduction

ModuLine, a name born from the idea of “modulating the lines,” is a simple yet effective device designed to bring much-needed order to the often-chaotic world of IV line management. Its core purpose is to prevent the frustrating and potentially dangerous problem of tangled IV lines, ultimately improving both patient safety and clinical efficiency. At its heart is a base platform that securely attaches to the bed rail, a foundation upon which a range of modular attachments can be added, opening up possibilities for streamlined infusion management.

More than just a bedside tool, ModuLine serves as a case study in how small-scale, clinician-driven innovation can solve real-world problems. The project demonstrates that R&D doesn’t require millions of dollars, corporate sponsorships, or extensive bureaucratic processes. With accessible tools, iterative design, and direct user feedback, meaningful solutions can emerge from those who experience the problem firsthand.

In healthcare, we often assume that change must come from the top down—through major institutional efforts or industry-backed products. However, ModuLine demonstrates that real, practical innovation is just as likely to come from the bedside, from those who truly understand the challenges of patient care. By embracing creativity, iteration, and direct user feedback, healthcare professionals can take an active role in designing their own solutions—ensuring that innovation remains practical, patient-centered, and clinician-driven.

The Problem: Makeshift Solutions and Market Gaps

The spark for ModuLine came from observing a common, albeit far from ideal, practice in hospitals: the use of makeshift solutions like tongue depressors (“popsicle sticks”) and medicine cups taped to the bed rails to manage IV lines. While some high-end beds, like those from Hill Rom, offer built-in adjustable holders, these are typically located only at the head of the bed, limiting their usefulness to IV lines originating above the nipple line. This leaves many other setups without adequate organization, forcing clinicians to rely on haphazard, improvised methods.

Existing commercial solutions, such as the IV Guard Line Organizer by Da Vinci Medical and OTEN Medical’s iLine, attempt to address this issue but introduce their own challenges. Many of these products are either prohibitively expensive or adhere to the bed using adhesives, raising infection control concerns and reducing their long-term durability. There was a clear gap in the market for a practical, affordable, and safe solution.

From Concept to Reality: A Grassroots Innovation

However, the ModuLine project was about more than just creating a product. It was also a personal exploration into Computer-Aided Design (CAD) and 3D printing, a hands-on demonstration of how grassroots innovation can thrive in healthcare. In a field that is heavily rooted in the sciences and often perceived as unconducive to creativity, the constraints of clinical practice ironically served to sharpen my creative problem-solving skills.

This project highlighted the power of learning by doing—embracing the iterative design process and capitalizing on the rapid feedback loop afforded by modern prototyping technologies. I purchased a $100 3D printer from OfferUp, spent $15 on filament from Amazon, and used free CAD software like TinkerCad and FreeCAD to develop my models. With minimal financial investment, I was able to create a working prototype and continuously refine it without the need for corporate backing or large-scale manufacturing.

The R&D Process: Iteration Over Perfection

The design process was a dynamic cycle of creation, testing, and refinement. Through approximately 15-20 iterations, the initial concept gradually evolved into its current functional form. The ability to rapidly prototype was absolutely crucial—a key advantage of working outside a traditional manufacturing process.

At work, I would bring prototypes to my coworkers, gather their feedback, and return home to make the necessary modifications. Before heading to bed, I would start a new print on my 3D printer, allowing the next iteration to be ready by the time I woke up. That night, I would bring the fresh prototype back to work, test it in real conditions, and restart the cycle. This instantaneous feedback loop—a cycle of create, adapt, iterate, and apply—ensured that the design evolved based on real-world usage rather than abstract assumptions.

This iterative approach is what made ModuLine truly pragmatic. Had I relied on a manufacturer, each adjustment would have been slowed by production constraints, cost, and communication barriers—fundamentally altering the design process.

Optimizing for 3D Printing

One of the key production challenges in 3D printing is dealing with overhangs—sections of a design that extend outward without support underneath. Most 3D printers build objects layer by layer, meaning that a steep overhang can lead to poor structural integrity or failed prints if not supported properly.

To mitigate this, ModuLine’s current production involves splitting the original model along a coronal plane, producing two halves that then snap together. This approach eliminates excessive overhangs, ensuring a cleaner and more reliable print. However, this introduced a new challenge: how to securely join the two halves without using glue or epoxy, which can be toxic and unsuitable for a clinical setting.

Snap-fit models for 3D printing exist, but none were well-suited to the specific needs of ModuLine, so I had to create my own. The solution was a custom rhombus-shaped projection that fits into a corresponding rhombus hole, allowing the two halves to lock together securely. This design ensures that stress at the attachment site is evenly distributed across the device, preventing weak points and maintaining structural integrity. Once the device is mounted on the side rail, the compressive force further stabilizes the connection, reinforcing its strength without the need for adhesives.

This approach not only allowed for a strong, tool-free assembly but also maintained the flexibility needed for future design modifications, ensuring that ModuLine could continue evolving while remaining practical for real-world use.

Final Design and Considerations

The current ModuLine design represents the culmination of this iterative development cycle. Some of the key design elements include:

• A base platform that matches the widest breadth of IV lines feasible to accommodate various tubing setups.

• Side barriers (“flatends”) ensure that lines remain securely within a central valley without excessive bulk.

• A deliberate decision to exclude clamps or locking mechanisms, as they could cause tubing to become taut and dislodged with sudden patient movement.

One of the most exciting aspects of ModuLine is its modularity. The base platform is designed to accommodate a variety of specialized attachments, each tailored to different infusion setups, ventilator setups, feeding tubes, and any other lines/tubes that enter the patient space, this enhancing overall organization. This approach ensures that ModuLine remains adaptable.

Future Development: Modular Expansion and Sustainability

Looking ahead, the next iteration of ModuLine will focus on modular attachments, expanding its versatility and functionality. The long-term vision is to create a system where nurses can customize their setup based on patient needs, making IV management as efficient and intuitive as possible.

Additionally, I plan to explore the possibility of biodegradable materials, allowing ModuLine to be used as a single-patient device without contributing to excessive medical waste. This would align with the growing emphasis on sustainable healthcare solutions, ensuring that innovation does not come at the expense of environmental responsibility.