To develop a model that was optimal for IHR practice, the team opted to create a virtual 3D model  of a 2-year-old child. The structures that were segmented in the creation of the model were determined based on findings from normal contrast-enhanced computed tomography (CT) scans of both male and female patients aged 3-7. To limit the impacts of small patient size and radiation treatment on anatomical accuracy, a CT scan of a 7-year old patient was scaled to model the 2-year old following validated protocols. After being validated by a radiologist the model was manufactured.

Combinations of silicone, mesh, and thread were utilized to create low-cost skin, the aponeurosis of the external oblique, preperitoneal fat, cremaster muscle, retroperitoneum, and peritoneum. Other anatomical structures such as ligaments and blood vessels were constructed from rubber, rope and thread. A condom was used to replicate the hernia sac.  

Using Computer Aided Design (CAD) software, a physical simulator was designed to encapsulate all 3D printed anatomical structures and to include modular sections for laparoscopic and open inguinal hernia repair cartridges. Through an iterative design process, all additive manufactured components were incorporated into the cartridge designs with detailed instructions on replacing and assembling the cartridges for both surgical techniques.