SUMMARY
The pathogens causing pneumonia are difficult to identify because a high quality specimen from the lower lung is difficult to obtain. A specimen collection device, named the PneumoniaCheck, was previously designed to collect aerosol specimens selectively from the lower lung generated during deep coughing to aid in the diagnosis of specific pathogens causing pneumonia. Nine verification tests were performed on the PneumoniaCheck. Verification testing demonstrates effective separation of upper airway gas from the lower airway gas (p<0.0001) and exclusion of both liquid and viscous oral material (p<0.0001) from the collection chamber. Testing also demonstrated the selective sampling of the lower airway, even during low volumetric flow rates or incorrect positioning of the device. Rapid prototyping, vacuum molding, and injection molding are all manufacturing options for the PneumoniaCheck. Rapid prototyping is slow, and usually only economic for small numbers of parts. For vacuum molding or injection molding, the PneumoniaCheck would need to be cut in half and molded, and then the halves connected with fasteners, glued, or welded. Vacuum molding is inexpensive, but there would be a lip at the connection of the two halves. Injection molding is inexpensive and fast. The PneumoniaCheck could be injection molded and then glued or sonically welded together. Verification tests were developed and performed, and the results demonstrate that the PneumoniaCheck successfully collects lower airway aerosols separate from upper airway aerosols, excludes oral contents, and captures pathogens in the filter, even during non-ideal conditions. After considering three different manufacturing options, injection molding was recommended for the device.