Brentwood Medical began manufacturing face shields in April 2020, in response to the personal protective equipment (PPE) shortages caused by COVID-19. As a custom packaging thermoformer serving the medical device, dental, and other healthcare industries, Brentwood had never designed or manufactured PPE, but this was a challenge they were excited to take on.
Brentwood’s internal design and operations teams collaborated on a design, 3D printed prototypes, and released new injection molding and die–set tools for production in record time. This process usually takes 6-8 weeks to complete, but the team’s sense of purpose and urgency enabled them to complete the project in just three weeks’ time.
The face shield product showcases Brentwood’s diverse plastics processing capabilities: the visor is made on an in-line thermoformer using clear, die-cut APET material, and the headpiece is injection molded out of polypropylene. These materials were chosen specifically so the product could be disinfected in the field, enabling multiple uses.
Brentwood’s face shields are being shipped all over the world, and many are being donated to hospital networks and essential businesses in the areas where Brentwood operates. These activities are possible thanks to the cross-functional team members that pushed boundaries and expanded capabilities to complete the project. They were recognized company-wide for their get-it-done attitudes and willingness to go the extra mile during this difficult time.
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