Infrasonics, Inc. of San Diego asked Fallbrook Engineering, Inc. to assist them in designing a reusable housing with a disposable filter cartridge for their Star Products mainline respiratory filter. The project involved product design, material selection, manufacturing process development, vendor selection and mold design to yield a satisfactory commercial product.

Fallbrook Engineering determined that a die-cast aluminum housing would provide the most cost-effective solution. Because it was necessary to have a thin wall for optimum heat transfer, impregnation was required to make the housing hermetic.

Appropriate vendors were selected to generate tooling, die-cast the housing and fabricate the pleated filter insert. This product was tooled, completed and placed on the market according to a rigid marketing schedule.

Star Products mainline respiratory filter has been on the market for a number of years and continues to be the standard in the industry for this type of filter.