Drawing and storing whole blood using a 3D printed bottle cap and a disinfected 500 mL drinking bottle—A proof‐of‐concept study: Part 2

Abstract Background Disruptions in supply chains during crises and wars necessitate innovative solutions for blood collection. This study evaluates the feasibility and safety of using a 3D‐printed bottle cap (BC 2 L) with a standard 500 mL drinking bottle for whole blood collection as an alternative to traditional systems. Study Design and Method We conducted a feasibility study with 20 healthy adult volunteers. Participants were randomized to donate blood into either the BC 2 L‐drinking bottle setup (Test) or a conventional single blood collection bag (control). Blood samples were analyzed for hemolysis, bacterial contamination, and mechanical integrity immediately post‐donation, and at 24 and 72 h. Donation time and donor safety were also assessed. Bacterial growth testing and hematological analyses followed sterile procedures to measure hematological quality. Results Blood collection was completed within a mean time of 7 min across both groups. Hemolysis levels remained below clinically significant thresholds in both setups, and no bacterial contamination was observed. While the BC 2 L system demonstrated effective blood collection, minor leakage was noted in some bottles during transportation, attributed to the limitations of the 3D‐printing process. Conclusion The BC 2 L system represents a feasible, low‐cost alternative for whole blood collection in resource‐limited or crisis settings. It demonstrated comparable safety and mechanical integrity to standard systems. However, manufacturing refinements are needed to address leakage during transport. This study supports the potential of the BC 2 L as a valuable tool for enhancing medical preparedness in austere environments.