Background This paper describes the development of a new airway device that will improve the speed and safety of endotracheal intubation in anaesthesia and critical care. Case of need, design specification and fabrication of the steerable bougie mechanism is discussed. Aims Identify the need for a novel steerable bougie whilst considering technology readiness levels associated with medical device design. Analyse and produce suitable mechanisms utilising smart materials to increase device functionality aiding successful patient intubation procedures. Methods This work describes the total design activity that contributes to the successful development of medical devices, from case of need, to smart material actuation mechanisms. Research focuses on identifying a suitable control mechanism to allow a steerable tip to be integrated into a bougie with a control device attached to the laryngoscope. Results Data collected from a user group survey supported the development of a novel bougie, with better shape retention, variable rigidity within the tip, and an integrated steerable function. Analysis of several mechanisms, artificial muscles, and smart materials identified a cost-effective steerable mechanism that can be incorporated into a bougie. Conclusion Users have defined a need for an improved bougie. Controlling smart materials and mechanisms, within the predefined dimensions, identified strengths and weaknesses associated with steerable functions. The performance of the selected mechanism for incorporation requires a high level of control to accurately steer a device within the human airway.