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Purpose

Tracheobronchial stents are commonly used in airway management as a form of palliation for obstruction. This form of therapy immediately relieves the patients from life‐threatening conditions and significantly improves their quality of life. In the cases of complex tracheobronchial obstruction, customised airway stents are required for effective palliation. In this work, an Airway Stent Customisation Protocol (ASCP) is introduced.

Design/methodology/approach

It describes two variant routes that use a combination of rapid prototyping (RP) and rapid tooling (RT) techniques to fabricate customised airway stents in short lead times. The ASCP allows the stents to be tailored in terms of geometry, and distending strength. A brief comparison between the ASCP and other RP/RT manufacturing routes is also carried out.

Findings

The ability to customise airway stents in short lead times is important as it allows surgeons to swiftly treat life‐threatening conditions arising from tracheobronchial obstructions. It is shown that the ASCP is capable of providing relief to patients quickly. The application of RP and RT in the ASCP has not only allowed shorter response time to patients, but has also allowed the stents to be produced at a relatively low cost.

Originality/value

Tracheobronchial stents are commonly used in patients facing advanced stages of cancer. Focuses on a time and cost‐effective solution that is provided to improve their quality of life.

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