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Custom Filter Design

High-performance custom filters designed & manufactured low-cost from the beginning. Jumpstart your design cycle today.

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Custom Filter Design

ISO 9001:2015 CERTIFIED
Consistently providing products that meet customer and regulatory requirements

MERV 8-16, HEPA & ULPA
All the way up to 99.9999% efficient @ 0.3µ

Wide Variety of Materials
Customize your filter media and frames

In-House Testing
Measuring efficiency and pressure drop

Custom Industrial and OEM Filter Manufacturing

Since our founding in 1959, RP Fedder has been engineering and manufacturing custom filters for customers across every industry. Our filtration specialists will work with you to determine the type, size and materials that best suit your needs from custom HEPA filters to die cut filter media. We specialize in low-volume, niche applications, with production run sizes from a couple dozen up to thousands of pieces. We also provide short lead times ideal for manufacturers’ just-in-time (JIT) and lean production environments.

HEPA pleating machine

Designing the Best Solution for Your Unique Needs

Our engineers will work with you to understand your unique filtration and production needs and will optimize the tradeoffs inherent in any filter design to provide you with the filter that best fits your application. We’ll help strike the best balance across all of these areas:

  • Desired Air Flow
  • Filter Efficiency & Lifespan Needs
  • Pressure Drops
  • Geometric Constraints
  • Manufacturing Costs

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Filter Production Capabilities

Our Rochester, NY manufacturing facility has a wide range of production capabilities, including assembly & conversion. If you don’t see it below, please just ask. Chances are we can accommodate the custom filter design you need.

Pleating Capabilities

Testing & Certification

Filter Frames / Housings

Shapes and Configurations

Gasketing

Potting

Ultrasonic Welding

Die Cutting

  • Wide range of media including paper, synthetics, glass, fiberglass, HEPA/ULPA, ASHRAE/expanded metal, electrostatic, nanofiber and more
  • 1/2″ to 6″ high and up to 42 inches wide
  • Testing & certification
  • Pleat manufacturing performed inside a 10,000-class clean room

In-house testing is one way we ensure performance and quality while saving our customers money. The tests conducted in our lab and wind tunnels monitor airflow and particle capture efficiency. Each filter is labeled noting filter efficiency, pressure drop, rated air flow, serial number and lot number for unit tracking to meet our quality assurance standards. Additionally, we often work with 3rd party laboratories to have our products tested as requested.

Our capabilities also include 100% HEPA testing

  • Metals
    • Stainless Steel, Galvanized Steel, Galvanized Aluminum, Powder Coated Steel and Aluminum and more.
  • Polymers
    • HDPE, LDPE, PET, ABS, Glass Filled Nylon, Polyurethane, High Density Foam and more.
  • Beverage Board
  • Chipboard
  • Cardboard
  • Low-volume molded endcaps
  • Custom-injected

We have the capability to make any shape you want, even if we haven’t done it before. Our most common shapes and configuration options:

  • Cylindrical
  • Curved Panels
  • Flat Panels
  • Box
  • Square
  • Round
  • Cones
  • V-banks
  • With or without sealing gaskets
  • Options include foam-in-place and die cut in a wide range of materials
  • Options include hot melt, urethane, silicone

The ultrasonic welding process provides lower resistance and allows filters to be manufactured without stitch holes in the media, all while maintaining durability

Our high-speed presses handle high volume jobs and our 60” wide press can be used for larger part geometries

Custom Filter Design Case Studies

Redesigning Research Cage HEPA Filters
For Form, Function and Financial Goals

A longtime manufacturer of life sciences research cages approached R.P. Fedder when the existing design of the filtration system in the cages was no longer profitable or meeting customer needs.

Read Case Study

New Medical-Grade Consumer Air Purifier
Designed with No Time for Trial and Error

An air purifier manufacturer saw the opportunity to build a higher-performance product in response to the COVID-19 pandemic and partnered with R.P. Fedder to bolster their design team.

Read Case Study

Meeting Unique Time & Volume Needs
With Flexible Volume Assembly Line Capabilities

A global manufacturer of filters needed a contract manufacturer who could handle time-critical orders from 100 filters up to 1,000’s of filters while maintaining high quality standards.

Read Case Study

Common Applications

RP Fedder has been manufacturing filters for just about every industry since 1959. Our engineers work with you to determine the best filter design, whatever your product. Just some of the applications for which we’ve fabricated filters include:

  • Medical products
  • Dust collectors
  • Smoke & fume evacuators
  • Commercial vacuums
  • Venting filters
  • Animal testing cages
  • Cabin filters
  • Pre-filters
  • Industrial Air Filter Manufacturing
Custom Filter Manufacturing

OEM / Custom Filters

Custom HEPA Filters

Air Purifier Filters

Die Cut Filters

Dust Collectors

Digital Printing Filters

Foam Filters

Medical Filtration

Pre-Filtration

Laboratory Filters

Panel Filters

Industrial Vacuuming Filters

Weld Smoke Evacuation Filters

We make a wide variety of filters for the most demanding OEM filtration applications including specialty and niche markets. Rugged elastic PVC end seals are cured with molded sealing beads to allow compression to eliminate contaminated bypass. Our filters are designed to meet the demanding airflow and efficiency requirements of the semiconductor, pharmaceutical, biotech, food processing, and other industries in which airborne contaminants must be carefully controlled.

  • Pleating
  • Die Cutting
  • Ultrasonic Welding
  • Assembly
  • Testing & Certification

As one of the leading global producers of HEPA (High Efficiency Particulate Air) filters, we design and manufacture an array of OEM, aftermarket and custom HEPA air filters for industrial, commercial, healthcare, and household products. HEPA filters as defined by the Institute of Environmental Science & Technology (IEST) must capture a minimum of 99.97% of contaminants down to 0.3 microns in size. This means for every ten thousand 0.3 micron particles that enter the HEPA filter, no more than three particles will pass through. We have state of the art manufacturing and testing facilities for HEPA and ULPA filters.

Just using HEPA media in a filter design doesn’t guarantee a true HEPA-performance filter. For instance, the filter and its frame need to be engineered with a tight seal so air and particulate isn’t able to go right past the filter without getting caught. We take factors like these into account when designing your filter to ensure it meets the highest quality and performance standards. Some of our custom HEPA filter design capabilities include:

  • Cartridge, Panel, or V-Bank
  • Tested in house to IEST standards
  • Pleated in class 10,000 clean room
  • Metal or molded frames/end caps
  • One piece or dovetail gaskets

Our air purifier product range includes pre-filters, high efficiency filters such as HEPA and ULPA, and specialty carbon filters.

  • Panel, cartridge or custom geometries
  • Pre-filters, HEPA, Carbon
  • Metal, chipboard, plastic, molded style frames/end caps
  • Built to meet OEM standards

We have high-speed presses for high volume jobs and a 60” wide press for large part geometries. If you have a die cut part you need, R.P. Fedder can help.

  • Small to large geometries (up to 55” wide)
  • Foam, ASHRAE, carbon, or laminated medias
  • Gasket materials include foam, neoprene, poron, etc.

Typical applications are vacuum systems, conveying systems, powder booths, and wood dust collection filter elements.

  • Standard and custom sizes available
  • Cellulose blends, Spunbond, PTFE membrane, nanofiber media available
  • Engineered solutions for troubled collectors
  • High-efficiency pleat design

We’ve been capturing pesky toner dust since 1959. In fact, that’s how our business began: designing and manufacturing the toner bag filter for the first generation Xerox machines. Our expertise and longevity in this industry has made us a key supplier of filters, cleaning and oiler belts, and bottled silicone fluid for manufacturers around the world.

  • Toner filters
  • Oiler belts
  • Ozone filters
  • Bottled silicone sluid

Foam air filters are available in a variety of reticulated open cell polyester, polyurethane and polyethylene foam filter medias. Applications include vacuum cleaners, appliances, industrial equipment, cabin air filters, CPAP, oxygen concentrator filters, dental appliance air filters, electronic equipment air filters, HVAC air filters, medical equipment air filters, and specialty filters for our military.

  • Cartridge wraps
  • Ultrasonic welding
  • Laminating gradient densities available

Medical filters include carbon filters, cartridge filters, capsule filters, disc filters, foam filters, HEPA filters, panel filters, pre-filters and ULPA filters used in a variety of medical appliances and equipment.

  • Specialty molding available
  • On-site testing and certification
  • Pleated in class 10,000 cleanroom

Using a vast array of filtration media, including, fiberglass, polyester, foam, melt blown, electrostatically charged media, etc., we can pleat, die cut, ultrasonically weld and frame a pre-filter to suit your needs.

  • Custom enclosures
  • HEPA and ULPA filters
  • Carbon trays
  • Fume hood filters
  • Isolation system filters
  • Custom and Standard sizes
  • Merv 7 to Merv 13
  • Electrostatic media available
  • Chipboard, metal or plastic frames
  • Printed frames available for private labeling

If you need a filter designed to meet EPA safety requirements for lead paint abatement or asbestos removal, we can help.

In welding operations, workers are in contact with harmful fumes like Hexavalent Chromium, which is made up of submicron particles – detrimental to human lungs. Our HEPA filters eliminate those harmful particles and carbon filters aid in fume reduction.

  • Certified filters to remove Hexavalent Chromium
  • Industrial strength build quality

Start the Conversation With Our Filtration Specialists

Please fill out the form below and one of our filtration specialists will reach out to help you select the right solution for your needs.

Custom Filter Design RFQ
Is this product already in production? *
Can you send us a sample of the filter that you currently use?