Bringing a Safer Airway Device to Life
Surgicure Technologies, Inc. came to us with a big idea: to transform how endotracheal tubes are secured—making airway management safer for both patients and clinicians. Their goal was to eliminate preventable dislodgements and device-related pressure injuries, particularly in trauma, burn, and prolonged surgical settings. They had an early proof-of-concept prototype, a clear purpose, and a commitment to safer patient outcomes, but they needed a partner to help bring it all together.
Content Warning: Case study contains graphic images of intubations.
The Challenge
Unplanned extubations and facial pressure injuries remain persistent, high-cost issues in both surgical and critical care. Traditional tube holders and adhesive methods often fail under blood, sweat, and motion—especially in trauma and burn cases where the face cannot be used for fixation. Surgicure’s early prototype demonstrated promising functionality but required refinement to meet clinical workflow needs, simplify use, and withstand rigorous production standards. The company needed a partner who could optimize both form and function while preparing for tooling, manufacturing, and scale-up.
Production Ready Innovation
The Solution
We worked closely with Surgicure’s engineering and clinical teams to develop the HORSESHOE™ into a production-ready device centered on human factors and intuitive use.
Our industrial design team developed several visual communication options to deliver ergonomic grips and material textures that support one-handed operation, even with gloves and moisture.
The final design—now commercially launched as the HORSESHOE™—balanced clinical performance, safety, and manufacturability. It secures the endotracheal tube intraorally, maintaining oral care access and eliminating facial contact points to help prevent pressure injuries and dislodgements.
The Result
A Small Device with Big Impact
What began as an early prototype has evolved into a purpose-driven medical device designed to improve airway safety across hospital, prehospital, and military settings. For Surgicure, the HORSESHOE™ represents a major step toward redefining the standard of care in airway management. For clinicians, it delivers greater reliability and efficiency. For patients, it’s one less preventable risk.
References
Rastogi, Layon (2021), Endotracheal Tube Fastening Device-Related Facial Pressure Ulcers. The Cureus Journal of Medical Science.
Curran, Tredget (2017), Ivy Loop Wiring: A Useful Form of Endotracheal Tube Stabilization in Burn Patients. Plastic Surgery.
Cancio, L. (2009), Airway Management and Smoke Inhalation Injury in the Burn Patient. United States Army Institute of Surgical Research, JBSA Fort Sam Houston, TX 78234








