Respirator Lens Mold Building, Injection Molding & Custom Coating

Client Description

Bacou-Dalloz is a world leader in the design, manufacture and sales of Personal Protection Equipment, operating across 5 continents with approximately 6,000 employees. The Group specializes in providing head-to-toe protection specifically designed for use in all sectors where men and women are at risk (manufacturing, construction, telecommunications, homeland security, medical, public services, etc.) and offers a complete range of head and respiratory protection equipment.

The Challenge

Bacou-Dalloz was introducing a new and improved respirator into the market. The design of the lens was very intricate and was critical to the performance of the entire mask. The respirator had to offer the following:

  • Excellent field of vision
  • Maximum safety, comfort, and wearer acceptance
  • Double sealing flange for optimum fit
  • Distortion free lens
  • Anti-fog and abrasion resistance to provide outstanding optical clarity in the most demanding environments
The MXL Solution
MXL met every one of Bacou-Dalloz' challenges by designing and building a very complex optical-quality plastic injection mold with numerous auxiliary "actions" to produce the double flange, as well as the many mating surfaces required for the canisters and filters. The result was one of the premier lenses in the respirator industry, from one of the best tools ever designed and built to produce an optically correct plastic part.

However, Bacou-Dalloz' challenges weren't completely met until MXL could mold such a critical and complex part in optical grade polycarbonate and cost-effectively apply abrasion resistant and anti-fog coating to the lens. MXL's diverse experience as a mold builder, injection molder, and custom coater of optical plastic parts was essential to Bacou-Dalloz' success.

MXL Industries, Inc. - 1764 Rohrerstown Road, Lancaster, PA 17601
Toll Free: 800.233-0159 - Local: 717.569.8711 - Fax: 717.569.8716 - Email: