Since we’re not happy with the status quo, we’re always looking for new ideas and ways to improve. Our commitment to these goals is reflected in the work of our development department, which specialises in finding customised solutions for individual challenges. Our area of expertise covers the development of products in the field of respiratory and occupational safety, as well as the development of assemblies, textile products, hardware and software solutions for testing facilities to verify product requirements and test benches for conducting tests in accordance with EN and ISO standards.
In addition to our own product development, we also carry out contract development work according to the specific requirements of customers, users, authorities or suppliers. Furthermore, we actively participate in research and development projects for new occupational safety solutions, which are carried out as part of funded individual, cooperation or joint projects with manufacturers, companies, research institutes, universities or our customers.
E-BREATHE SAFETY RESEARCH AND DEVELOPMENT DEPARTMENT
Benefit from our extensive know-how and over 30 years of experience in respiratory protection and occupational safety. Our research and development team has broad expertise in various fields and, through its involvement in the DIN Standards Committee and the IVPS (Interest Group for Personal Protective Equipment), is always well informed about current and future technical requirements and the changing market situation.
Our R&D team consists of qualified specialists, including industrial designers, mechanical engineers, textile and electrical engineers, and industrial engineers. They take care of all aspects of product development, from brainstorming and conception to prototype construction and testing, certification, production, and quality control.
Interdisciplinary collaboration between research and development and our other departments—sales, technical service, purchasing, production, and logistics—provides support and knowledge transfer.
This continuous interdisciplinary exchange forms the foundation for the optimal integration of customer feedback, market requirements and efficiency improvements. This enables us to respond quickly to potential challenges and seamlessly incorporate the insights gained into the development processes.
OUR ENGINEERING SERVICES
Development
Project Management Planning
Design
The planning phase is a crucial step in the product development process, laying the foundations for a product’s success. Every development begins with a problem, which in the best case scenario has already produced a good idea as a solution. This idea should already exist and may have been further developed through brainstorming, customer feedback, the identification of market gaps or market research.
We get to the bottom of this approach, check its feasibility, analyse the project in terms of economic viability and research the technical and legal framework conditions. If necessary, we will prepare a detailed feasibility study for you or present you with alternative solutions to your concept. The results of these investigations form the basis for the further development of concepts in the next project phase.
Feasibility Studies
A feasibility study serves to conduct a thorough investigation that assesses the economic, technical, legal and operational feasibility of a project or business idea. Its aim is to clarify the central question of whether the planned project is feasible and profitable. We offer to carry out this study either partially or in full in order to provide you with a sound basis for your decision-making.
Our Services
- Analysis of Product Requirements
- Determination of the state of the art
- Creation of design, product and ergonomics studies
- Support with problem analysis and solution finding
- Creation of project plans
- Market and competition analysis of existing products/services/providers
- Creation of a requirements catalogue
Subsidy consulting
For more than a decade, we have been working successfully with colleges, universities, research institutions and partners from industry and the personal protective equipment manufacturing sector on research and development projects as part of various German government safety research programmes. This long-standing collaboration has led to the creation of numerous projects that have resulted in innovative product developments, new protective functions and application concepts, as well as automated test benches and improved testing procedures. Each of these projects has helped to expand our expertise in various fields and seamlessly integrate these findings into our development processes.
In order to continue to be innovative and become a pioneer in innovative respiratory protection products, we are always ready to participate in such research and development projects as a partner or to advise companies on how to apply for and obtain funding.
We prepare the project application internally, providing a comprehensive project description, a detailed project plan, an exploitation plan and all cost statements. If the project is approved, we are happy to provide support in processing and correctly applying for payment instructions.
We have already successfully participated in various types of funded projects from different project sponsors, including individual projects, cooperation projects (companies or universities) and joint projects (companies, universities, research institutions).
Projects carried out with the German Federal Ministry for Economic Affairs and Climate Protection (BMWK):
- ZIM (Central Innovation Programme for SMEs)
- Innovative Protective Equipment Funding Programme
- De-minimis-Aid
Projects carried out with the German Federal Ministry of Education and Research (BMBF):
- SME Innovative: Research for Civil Security
- FHprofUnt: Research at universities of applied sciences
Our services in subsidy consulting
- Support in selecting a suitable funding programme
- Support in preparing the project application
- Support during the funding project if approved
Development
Product development Concept
Concept phase
Based on the idea, preliminary planning and any prior market and feasibility analysis, the foundation for successful and targeted development is laid in the concept phase. We rely on creativity, methodology and a systematic approach. In this phase, fundamental ideas and concepts are developed to test the feasibility and prospects of success for a new product. Various approaches and solutions for the planned product are developed and evaluated here. The most promising concept(s) are implemented in the next phase of development/detailing. In addition, the requirements and specifications are updated based on the findings from the concept phase, using new key data and framework conditions.
Our services
- Development of various solution concepts
- Concept design and sketching
- Design elaborations
- Creation of models for illustration purposes
- Evaluation/selection of concepts
- Support in creating specifications and requirements documents using existing templates and checklists
Development
Development Construction
Konzeptphase
Our R&D team consists of qualified specialists, including industrial designers, mechanical engineers, textile and electrical engineers, and industrial engineers. They take care of all aspects of product development.
During the development phase, we strive to ensure optimal functionality within the specified time and budgetary constraints. A key focus is on creating a precise specification sheet, which serves as a basis for our work. Based on this, our engineering teams develop components and manufacturing components. During the design process, our employees independently select suitable materials, independent of raw material manufacturers and distributors.
Our services
- Creation of CAD designs for 2D/3D models
- Integration of functionality, ergonomics, quality and costs, as well as design aspects
- Involvement of design and engineering to check the technical feasibility of designers' creative work
- Creation of CAD/CFD simulations
- Creation of sewing patterns
- Development of circuit boards, layouts and software
- Product development and development of test benches
- Design and manufacture of test equipment (e.g. test heads, torsos, etc.)
- Detailed elaboration of existing designs and concepts
Development
Prototypes & Functional Models in the Makerspace
Our development processes are supported by state-of-the-art technology and in-depth expertise. Our in-house makerspace is an important part of our development department. Here, we can create prototypes, demonstrators and functional models in a very short time to test and improve the functionality and efficiency of our development work. Our makerspace promotes cross-departmental creative collaboration and knowledge exchange. People from different backgrounds and with different skills are invaluable, especially for prototype development and rapid testing of ideas.
We use advanced CAD design software, 3D printers (FDM/SLA), 3D scanners, laser cutters, vacuum forming machines and sewing machines to create precise models. In addition, we have modern testing equipment that enables us to manufacture prototypes and conduct tests in our laboratory. This combination of technology and expertise forms the basis for the development, production and manufacture of high-quality and safe personal protective equipment. Our in-house makerspace and laboratory are crucial to our development department and enable us to continuously drive innovation and ideas forward.
3D-Printer
3D-Scanner
Laser cutter
Sewing machines
Prototype casting
Vacuum forming machine
Development
Orientation tests Test implementation
In product development and the development of technical systems, tests and trials are carried out to verify the suitability of concepts. This includes, among other things, proving functional efficiency, mechanical strength and durability. Individual functional areas, components or the entire system are replicated by developing prototypes and then tested.
Our many years of experience in the development of various respiratory protection products, active participation in various research projects and careful quality assurance of our manufactured products have led to the decision to set up a modern laboratory with a wide range of test benches developed in-house.
This enables us to carry out a large number of preliminary tests during the development process or for external products and partners that meet the requirements of EN and ISO standards. Our experienced test engineers carry out tests in accordance with the applicable norms and standards. In doing so, we not only test compliance with and fulfilment of valid norms and guidelines, but also intensively examine the limits of use of the products and functional models in the development process and determine the point at which the requirements are no longer met in order to gain precise insights into the performance of the products.
Our services
- Planning, development and construction of test benches
- Functional testing of prototypes during the development phase
- Testing and evaluation of products prior to certification
- Orientation test according to EN/DIN/ISO standards
- Determination of operating limits
Our services
- Preparation of detailed test reports
- Development of test and trial procedures
- Support during exams
QUALITY AND ORDER CHECK
We offer external quality and order inspections as well as a wide range of orientation tests during the development process and inspections of production batches for external products and partners that meet the requirements of EN and ISO standards.
Testing and Inspection equipment
As a research and development-oriented company, we have made it our mission to develop our own test benches and testing equipment. This includes both the hardware and the associated software, including ISO test heads and other necessary testing equipment.
Development
Production and manufacturing
With successful certification, the development process is complete. The product goes into production. We organise and support all processes in the necessary production chain. From pre-series to series production, we manufacture exclusively in Germany and EU countries – this guarantees short delivery routes. When selecting production partners, we place the highest demands on quality.
In our final phase, production, we offer a wide range of services to ensure that products are manufactured efficiently and to a high standard of quality. We create detailed production and manufacturing documentation and plan and implement pre-series and pilot series to ensure a smooth production environment. At our site in Mönchengladbach, we take care of component assembly. The production of textile products is carried out within Europe by certified PPE manufacturers in accordance with our strict quality specifications.
Our services
- Assembly of components
- Procurement planning, enquiries and coordination of components and assemblies with suppliers
- Preparation of production and manufacturing documents
- Planning and implementation of pre-production and pilot series
Our Services
- Testing and optimisation of the production and quality process
- Provision of quotations for injection moulding tools and support for these tools throughout the entire manufacturing process up to approval
- Series support after market launch