From Import to Innovation: Supporting Domestic PPE Production with Custom Materials

Background

A new customer who specializes in the production and distribution of high-quality personal protective equipment (PPE) for the healthcare industry contacted PGC for assistance in sourcing a component for their line of protective masks. This company is 100% American-owned and operated, taking pride in tackling supply chain issues and shortages by providing a reliable, domestically produced source of personal protective equipment. They sought out PGC's expertise in analyzing applications and delivering informed solutions for custom requirements. 

Challenge

The customer set out to shift their production operations from an overseas facility to a fully domestic manufacturing process, with the goal of having their parts made exclusively in the United States. This strategic transition was driven by a need for increased supply chain security, improved lead times, and, most importantly, compliance with the Berry Amendment—a federal regulation that mandates all stages of production, from raw material sourcing to final assembly, must take place within the U.S. to support domestic industry and national defense interests.

While the customer approached the project without finalized part drawings, designated materials, or specific adhesive preferences, they did provide helpful guidance by referencing the type of components they had used in the past. This allowed for an open collaboration with our engineering team to propose suitable alternatives that would meet both performance requirements and compliance standards. Furthermore, the customer expressed an interest in exploring new material options—specifically ethylene-vinyl acetate (EVA)—to assess potential improvements in durability, flexibility, or ease of fabrication. The use of EVA would require a shift in production methods compared to the materials previously used, adding an extra layer of complexity to the project. However, this also presented an opportunity to innovate and optimize the part for both manufacturing efficiency and long-term performance in its intended application.

Solution

To identify the most suitable material for the application, our application engineers created detailed prints and provided the customer with a variety of material and adhesive samples.  Each sample was chosen based on unique performance requirements such as surface energy, temperature resistance, and bond strength.  

Our team worked closely with the customer to assess every option, carried out real-world trials, and shared manufacturing insights to help lower costs through optimized material usage and streamlined production. Furthermore, our team ensured that all proposed solutions complied with Berry Amendment requirements, supporting the customer’s sourcing and regulatory obligations without compromising quality performance. 

Result

After reviewing various prints and samples, our application engineers successfully identified a solution that met the customer’s application needs, while ensuring Berry compliance. With this information, we developed two separate part programs consisting of two components that were identical in every way except for their dimensions. The customer was excited to partner with our team, as we were the only company willing to engage in the process and develop the part with a focus on Berry Compliance.