fablab@aup.ac.uk
SageTech: recycling anaesthetic gases to cut emissions in healthcare
Projects

SageTech: recycling anaesthetic gases to cut emissions in healthcare

SageTech partnered with Fab Lab South West to prototype components for an anaesthetic gas capture and recycling system — accelerating R&D from concept to pilot and supporting a lower-carbon future for operating theatres.

Sagetech partnered with Fab Lab South West to prototype and develop equipment for anaesthetic gas capture, addressing one of healthcare’s most pressing environmental challenges. Anaesthetic gases, which have long atmospheric lifetimes and high global warming potentials, contribute significantly to the sector’s carbon footprint. The equipment designed in partnership with Sagetech captures these gases, preventing their release into the atmosphere and helping to mitigate healthcare’s impact on climate change.

Building on this foundation, the collaboration moved rapidly from CAD training to iterative prototyping of bespoke parts for extraction, chromatography and scavenging systems — helping de-risk Sagetech’s path to pilot manufacture and scaling.

The challenge

Inhalational anaesthesia underpins modern surgery, yet the majority of the agent delivered to patients is exhaled and vented to atmosphere. SageTech set out to capture, purify and return these agents to the supply chain, reducing environmental impact while improving access and efficiency in theatres.

Our approach

  • From skills to collaboration: Following initial CAD training accessed via a regional programme, SageTech engaged Fab Lab South West to explore advanced manufacturing routes suitable for regulated medical environments.

  • Iterative prototyping: Fab Lab South West supported design for manufacture and rapid iteration of bespoke components for extraction and chromatography units and for an anaesthetic gas scavenging system. Multiple additive and subtractive processes were trialled to select the most appropriate technologies and materials.

  • Choosing the right process: Side-by-side evaluation of FDM, SLA and SLS 3D printing, alongside CNC machining and laser-cut assemblies, enabled fast turnaround, tolerance and leak testing, and assembly checks before pilot builds.

  • Design assurance: Collaborative reviews focused on fit, flow paths, sealing, heat and chemical compatibility, producing manufacture-ready prototypes aligned to SageTech’s pilot timelines.

Results & impact

  • Faster time-to-pilot: Rapid concept-to-prototype cycles with tolerance and leak testing reduced development risk and timelines for multiple machine sub-assemblies.

  • Scaling locally: SageTech established a pilot production facility in Paignton to support trials.

  • IP secured: Prototyping evidence underpinned international patent activity.

  • Sector recognition: The technology received the Association of Anaesthetists Award for Innovation (2020).

  • Path to scale: Subsequent collaboration with a global med-tech partner explored larger-scale deployment, while Fab Lab South West delivered ‘Innovation in Meditech’ workshops for anaesthesiologists in Marseille, sharing accessible routes into digital design and advanced manufacturing.

Technologies used

3D CAD (Fusion 360) • 3D printing (FDM / SLA / SLS) • CNC machining • Laser cutting • Assembly & fit testing • Design for manufacture

Partners & credits

  • Industry partner: SageTech Medical Equipment — Dr Sebastian Brown (Research Director), Matt Gopal (Head of Commercial & Veterinary)

  • Fab Lab South West, Arts University Plymouth: Advanced prototyping and design support

  • Programme context: Collaboration originated via the Impact Lab network supporting SME innovation in the region

Arts University Plymouth liaison): Ian Hutchinson, Director of Development & Partnerships

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