How a start up pivoted to help during the pandemic

Until mid-March 2020, Lake Effect Medical was a Chicago-based startup innovating orthopedic equipment for those recovering from injuries or medical procedures. Our mission was to improve patient outcomes, lower the cost of care, and reduce narcotic consumption with our wraps, braces, slings, and cold therapy technology. In designing products for the surgical environment, it is essential to prevent infection, as bacteria and viruses may cause complications or even death. That's why we employed antimicrobial technology to ensure our products were safe for medical use and home recovery.

But when COVID-19 hit, elective surgeries were put on hold, leaving Lake Effect Medical in wait. Still, we knew that we had the ability to pivot production and the access to technology that could make a difference in keeping people safe during the pandemic.

Pivoting production

We took that desire to do some good and immediately assessed the situation. I reached out to my partner Bryan Kilbey, the owner of Ezywrap, to discuss personal protective gear for the community: For people venturing out for groceries, doctor appointments, and other necessary tasks and for those essential workers who weren't on the front line but who kept our country up and running, from checkout clerks to transit operators to those in the food and shipping industries. We quickly began crafting 20 different prototypes of what would become the Venture MicrobeSafety Mask.

From the start, it was important for us to create a reusable face covering with more protection than a cotton mask but that was still breathable enough to wear all day. Applying MicrobeCare, the nontoxic, EPA-registered antimicrobial coating we already used in our medical equipment, allowed us to add a permanently-bonded layer protecting against surface contamination of viruses and bacteria to our face coverings. These protective benefits would last one year, even with repeated washings. More importantly, previous testing showed we could use MicrobeCare to create an innovative product we trusted to keep our families, friends, and employees safe.

Another important factor in our prototyping process was achieving a secure yet adjustable fit for anyone, from kids to adults. We opted for a lightweight fabric that could be easily cut to fit smaller faces and added Velcro ear loops that adhered anywhere on the masks' surface to make them truly customizable.

Working in partnership with Ezywrap, it took about ten days to pivot and begin manufacturing masks at scale. We settled on a prototype, sourced fabric, and made changes in the plant before beginning round-the-clock production. Manufacturing had never operated under a three-shift schedule before so additional staff were quickly hired and trained. Protocols were updated to adhere to new health and safety guidelines for social distancing, including coordination with health care providers to send daily questionnaires to employees and order additional testing, if necessary.

Lake Effect Medical now produces thousands of masks daily and proudly offers the Venture MicrobeSafety Mask in bulk to employers looking to help their employees return safely to work and to schools needing solutions for students attending classes this fall.

For individuals, we created the Venture Safety Pak, which includes two masks and a 2-oz bottle of spray hand sanitizer. Finally, we made these kits available for direct shipping to multiple locations - for easy sending to family members and friends or to employees and students at their homes.

Giving back

Early in our process, we knew we wanted to do more to give back. As part of our commitment to the health care community, the proceeds from each mask sold go directly to Frontline Heroes, a nonprofit dedicated to providing health care workers on the front lines with the medical-grade personal protective equipment they need to stay safe. To date, through customer purchases, we have donated more than $80,000 to Frontline Heroes.

• Nathan Gray is co-founder and CEO of Lake Effect Medical, Graymont Medical, and other companies in Chicago and suburbs. For more information, visit www.lakeeffectmed.com.