How Additive Manufacturing Is Redefining the Laryngoscope - More Flexibility for Modern Medicine
08 March, 2026 | Reading time: 3 min
Laryngoscopes are among the most important instruments in clinical and preclinical intubation. They consist of a handle and a blade, which can be straight (Miller) or curved (Macintosh), and today are predominantly manufactured from metal or polymer. While in everyday clinical practice laryngoscopes are disinfected and reused, emergency medical services often rely on single-use versions. In routine clinical settings, these instruments are typically available in a limited range of standardized blade sizes, which are designed to cover the majority of patients.
Flexibility for Modern Medicine with AM
This is precisely where a decisive advantage of additive manufacturing becomes apparent: while standard sizes are sufficient for many situations, pediatric and patient-specific geometries are difficult and expensive to produce within traditional supply chains. AM, on the other hand, enables economically-viable production of very small batch sizes - including extremely small blade geometries tailored precisely to the anatomical requirements of children.
Functional Integration Instead of Process Chains
As an internal innovation project, an EOS expert team examined how a laryngoscope could be fundamentally rethought using additive manufacturing. Early development phases already showed that AM not only enables faster iterations but also allows for new functions or ergonomic features to be integrated directly into the part – without complex process chains or the need for additional assembly or machining steps.
One example of this is the integrated channel for optics: in conventional manufacturing, such elements require multiple milling or welding operations because the optical light source is completely enclused with in the metal or plastic blade. With AM, however, no extra production step is needed. The optical channel can be integrated into the design and thus produced with the part itself. This results in a component designed with less material, reducing material costs, and simplifying the design at the same time.
Another strong example of functional integration is the locking mechanism. Traditionally, this requires several individual components and assembly steps to ensure a secure connection between blade and handle. With additive manufacturing, key elements of the locking mechanism can be incorporated directly into the blade geometry itself. This reduces manufacturing complexity, eliminates separate assembly stages, and creates a more streamlined, robust overall design.
The Right Material: EOS Titanium Ti64
For the AM prototype of the laryngoscope, the team uses EOS Titanium Ti64, one of the most widely used titanium alloys in medical engineering. It is characterized by excellent mechanical properties, high corrosion resistance, low specific weight, and biocompatibility.
This combination makes Ti64 ideal for functional medical instruments that must be lightweight, robust, and safe in contact with patients - a key advantage over conventional metal variants, which are often heavier.
From the Idea to the Finished Part: The AM Development Process
For early development work, initial prototypes were produced directly in Ti64 using DMLS on an EOS M 290-2. Through optimized build utilization, up to 93 laryngoscope blades per build-job can be produced - a clear indication that AM is also attractive for functional metal components with medium production volumes.
In this study, both an AMoptimized version and a model functionally derived from an industrystandard design were produced. Both variants were designed to meet key requirements of the regulatory landscape, including ISO 7376 for dimensions and performance, as well as further applicable standards. Against this backdrop, the project also reflects EOS’ broader role in supporting customers along the qualification journey of medical devices – from surgical instruments to implants – by enabling repeatable processes, validated materials, and manufacturing concepts aligned with regulatory requirements.
During the design iterations, the team identified key challenges related to sterilization and residual stresses within the additively manufactured base structure. While the specific technical details of these issues were part of the internal development work, addressing them early in the process demonstrated how essential AM is for refining designs efficiently and safely. The iterative approach allowed the team to evaluate different geometries, understand how the chosen material behaves during and after the build, and incorporate insights that are critical for moving toward reliable series production – especially in applications where precision, safety, and robustness are fundamental.
“Projects like this highlight what many medical customers are looking for: faster development cycles, greater design freedom, and solutions that address real clinical needs. EOS brings the expertise to not only accelerate the development of new applications, but also to support product validation, leading to shorter validation pathways.”
Anna Sailor, Medical Expert, Additive Minds Consultant Metal
Additive Manufacturing Opens Up a Broad Range of Medical Applications
- Patient-specific and application-specific geometries
- Shorter development cycles
- Economically-viable production of small series
- Functional integration without additional process steps
- Decentralized production for flexible supply chains
This innovation story clearly demonstrates that innovation in the medical sector does not happen by chance - it emerges when technology meets expertise. And this is exactly where the laryngoscope project comes in: as an example of how AM helps make modern medical technology lighter, more functional, and more versatile.
Joint Innovation Project from AM Global and EOS.
