(Archive) CRN_01 "Hummingbird" Swabs

Inspired by need and nature

The CRN_01 "Hummingbird" design is a response to the logistics crisis at the beginning of the Covid-19 pandemic and shortages in medical supplies, reported directly by the medics with whom I have contact in my professional work. The project wouldn't have been possible without the consultation and invaluable expertise of these specialists.

In the spirit of biomimetics, the form of the swab was inspired by the hummingbird's tongue, adjusted to collecting nectar from flowers. The mechanics of this process and a diagnostic swab are similar enough to adapt nature's perfect solution to human needs.

The head of the CRN_01 swab is covered in rows of parallel grooves, like the tongue of a hummingbird. During the smear they direct the sample material to specially designed cavities that increase the volume of the sample, facilitating diagnostic testing and ensuring efficiency.

Moreover, due to the lack of flocks typical for this type of product, CRN_01 swabs “give back” for testing more of the collected sample than regular swabs – nothing gets trapped between the flocks.

The design process

Years of experience with advanced 3D printing and designs for injection molds have allowed us to create a project in the spirit of "rapid prototyping", in consultation with doctors and diagnosticians supporting us with their invaluable knowledge and expertise.

From the first idea, through dozens of prototypes printed on precise resin 3D printers, to the implementation of the first injection molded series, less than two months passed. Over a week of which was taken by the process of intricate electrical discharge machining of a four-cavity injection mold.

What makes it better?

The swabs available on the market are produced in two stages: injection molded and then flocked. In order to obtain the right parameters of the smear, specific flocks are needed, and therefore also proper machines and production lines for their application. The CRN_01 project, on the other hand, has a one-step production process, faster and cheaper – just the molding.

The design was optimized so that any company capable of injection molding can easily produce the swabs in times of need, without any additional equipment. That's the first time the decentralised production of this important diagnostic tools has been made possible.

As the CRN_01 swab has a one-step production process (only injection molding) and no additional flocks, it's made from single material. It means that it can be easily recycled and thus represents the circular economy approach.

The project passed diagnosticians’ verification and is a registered design. The first injection mold and production series were already made.

It is therefore a turnkey solution: optimized for mass production and with the potential to revolutionize the manufacturing of these specialized medical products worldwide.