"We are engaging with other Trinity Health hospitals across the country and looking at possibly setting up shops in other states, hoping this will help relieve some of the pressure as those global sources get back up to production," Chenard said.

Detroit Sewn had done work for clients all over the country in the apparel, home goods, automotive interior, pet products and even medical industries in the past. But those jobs were never at a run of 50,000 pieces, Detroit Sewn owner and CEO Karen Buscemi said.

"Who knew that domestic sewing factories would become such a critical piece of what's going on right now?," she said.

Trinity contacted Detroit Sewn on Wednesday to share its desperate need for masks, she said. A representative quickly brought over samples of the masks being used when it learned Detroit Sewn had capacity to sew.

The company had some of the 100-percent cotton woven fabric needed on hand — a material the virus doesn't like, Buscemi said — and was able to produce prototypes that were taken back to Trinity's hospital staff to ensure the pleating on them and way they conformed to the face to eliminate gaps would work.

The masks have different pleating so people of different sizes can wear them comfortably, Buscemi said. They can't have any gaps so the virus can't get in and have to be able to conform to people's noses so they don't gap.

The prototypes worked. Buscemi was able to get material quotes, freight costs and a delivery timeline together.



Trinity and Buscemi declined to disclose financial details of their contract.



She's hired five additional employees who will work with other staff to launch a first line of production Monday. Employees and machines will be spaced 6 feet apart, per social-distancing recommendations.



A week of ramp-up is needed to get materials in and cut them to the needed size, she said. But some production will begin right away with material the company has on hand.