The Challenge: a global manufacturer of industrial face masks approached Fulflex to improve the seals around the mask edges, which had above normal leakage causing high failure and scrape rates.
The Action: Our analysis showed that the valves were not sitting properly in their housing, causing them to fail the leak test. Material was drooping, which caused the seal at the edge to leak.
The Solution: Fulflex’s R&D group developed a new compound that sealed the edges, while remaining flexible enough to perform in the exhalation process. The result was a valve that decreased failure rates by 20% and performed significantly better. Fulflex’s superior gauge control was critical in improving customer yield by assuring proper seating of the valves as well as maintaining constant tension.