Custom Sewn Strap Case Study – Exceeding Pull Test Expectations

At Sturges in addition to weaving engineered narrow fabrics, we design, cut, sew, and test in-house, positioning us as a uniquely capable and qualified partner for your custom sewn products. Using our diversified inventory of webbing, thread, and hardware, we have the means and expertise to identify your problem, design, and manufacture a unique solution. Learn more about our custom sewing services.


We understand each challenge is an opportunity. The first step in the design process is to identify the challenge the customer is experiencing. A customer recently reached out to Sturges and explained they were having issues with the stitches tearing out of their current product. The customer expressed the sewn product would need to withstand a 5,000 lb pull test under ambient conditions.


After an in-depth conversation with the customer’s engineering team, we agreed the material and design were not an issue and could remain the same. The problem was identified to be the pattern of the stitch. By changing the stitch pattern and coordinates, we could drastically increase the product’s performance – beyond our customer’s expectations.


The design process is not complete until it is thoroughly tested and is deemed process capable. The Sturges Test Lab is registered to ISO 17025 and equipped with the necessary equipment to validate designs though standard test methods as well as documented custom methods. For this unique application our 35,000 lb vertical tensile tester was utilized to verify the strength of the stitch. The sewn product was pulled at 3″ per minute until failure. The stitch failed when the drop in peak load was greater than 90%. We were able to surpass the customer’s requirement and achieve over a 6,000 lb stitch. After testing, the results were shared in a formal test report with data and pictures. Samples were sent shortly after for customer approval, and once the samples were verified again in their lab, and their engineering team approved the change, Sturges was selected as the new supplier.


“It was a pleasure to work with Sturges. Sturges did a great job working with us to develop the exact strap that we wanted.”

Our industrial sewing capabilities can produce a custom sewn strap that exceeds your expectations. 

Contact Us Call Now

How Fire-Retardant (FR) Elastics and Proper Testing Help the Firefighting Industry

For Firefighters, having the right gear is paramount to ensuring their safety while protecting citizens from dangerous fires. Fire equipment involves many different elements – Self-Contained Breathing Apparatus (SCBAs), helmets, suspenders, goggles, boots, gloves, pants, and jackets are just a few of the critical pieces needed for firefighters to safely do their job. 

What often is not considered are the components needed to make some of these products. Fire Retardant or also called Fire Resistant (FR) elastics are one small part that literally holds certain pieces of gear together. For example, FR elastics are used and relied on heavily in the design of SCBA facepieces. Concerns arise when considering the possible damage of elastics hitting high temperatures and the potential to melt or drip, therefore a FR NFPA tested product is crucial.

Using fibers such as Nomex®, and blends of PBI®/Kevlar®, the FR elastics will not melt or drip in high heat due to the yarn’s inherent characteristics. Adopting a unique weaving process as well will ensure the elastic will not become wavy due to shrinking and will retain its stretch properties after heat exposure. Fire gear can be expensive and designing individual attributes like elastic to withstand multiple wears and various temperatures is unique and necessary.

FR elastics from Sturges Manufacturing come with many unique characteristics. When elastics are woven, monitoring tensions throughout the manufacturing process is necessary to ensure that the stretch is consistent. This allows the elastic to lay flat and prevents it from having a “ribbon effect,” or circular effect which makes it easier for a manufacturer to sew. Like many other performance webbings at Sturges, the elastics also go through a rigorous testing process all done on-site. All Sturges-made FR elastics have been sent to the Underwriters Laboratory to be UL Component Recognized to the NFPA 1971-2018 Standard for Structural Fire Fighting and Proximity Fire Fighting. This third-party validation means the manufacturer is not required to pay for heat and flame tests as these components have been independently tested and verified. 

In addition to the annual UL testing, Sturges performs vertical flame tests and records extinguish time as well as the char length (product must extinguish within two seconds and char length must be less than 4 inches). Heat tests are also performed in a 500º F oven — to pass, FR elastics must have 10% or less shrinkage and no evidence of melting, ignition, or separation. Testing is performed on five samples each for both laundered and non-laundered conditions to ensure the longevity of the elastic. Each lot of FR elastic is also stretch tested in accordance with ASTM D4964. A certificate of compliance accompanies each shipment defining the specifications and results as well

FR elastics are a critical component of many pieces of fire gear. They ensure not only the safety of firefighters but also the longevity and reliability of their equipment.

Have questions about FR elastics? Looking to quote fire-safe elastics for SCBA facepieces, masks, suspenders, goggles, or keepers for webbing tails? Contact us to request a quote here.

Leading Edge Header

Benefits & Features of Leading Edge Webbing

In the Fall Protection industry, few things are as important and highly prioritized as safety at height. Whether working on a telephone pole or a roof many stories above the ground, creating a safe environment for the worker is crucial.

In order to meet the unique needs of the industry, Leading Edge Self Retracting Lifelines (SRLs) were developed. Traditionally, these SRLs have been designed with heavy steel cables to protect a worker from a fall over a sharp edge. With the latest development in performance webbings, there is now a lightweight alternative to the steel cable SRL.

What does it mean for webbing and SRLs to be “Leading Edge”?

Per OSHA 1926.751, Leading Edge is defined as “the unprotected side and edge of a floor, roof, or formwork for a floor or other walking/working surface (such as a deck).” These unprotected edges leave workers suspended above them in a potentially precarious position. 

The presence of this edge creates an additional hazard — if someone falls and their SRL hits this unprotected edge, the combination of velocity, weight, and the sharpness of the corner is likely to snap a standard SRL not rated for leading-edge applications.

What does the process for developing Leading Edge webbing entail?

In the initial design phase at Sturges Manufacturing, testing goes beyond the requirements of the ASSP/ANSI Z359.14 in several key ways. Samples are abraded per FED STD 191A, Method 5309 and then dropped 6’5” using the ASSP/ANSI Z359.14 requirement with a 310 lb test mass and tested in a fixed position without an SRL.  After the dynamic test is complete in both the off-set and perpendicular position and the weight has been held for 2 minutes, the weight is pushed again to swing more on the edge for 5 additional minutes in multiple directions to ensure it can withstand the increased exposure over time. Once the sample is removed from the leading-edge test tower, it is then tested statically to verify the strength exceeds 1,000 lbs.   

Sturges is able to design prototypes and test them in-house in its state-of-the-art, ISO 17025 testing facility. The ability to test in-house also allows Sturges to provide a pre-tested product to clients during new product development saving time and increasing their speed to market.

While Sturges is focused on convenience for the customer, their own process remains detailed and custom — Sturges does not use another customer’s in-house results to market to other customers. Each prototype is unique and receives its own test data.

With safety being first, Sturges doesn’t only test during the design stage, but regularly during production as well. Dynamic testing is performed daily with each production run and monitored through SPC, to ensure a quality webbing that can be depended on.

Can Leading Edge Webbing be branded?

Leading Edge webbing can be customized to include custom colors and patterns. Sturges Manufacturing’s design and engineering teams work with customers to develop webbing that functions as intended and incorporates necessary branding.

Learn more about Leading Edge webbing and request a quote here.

Sturges Manufacturing Named One of the Best Companies to Work for in New York State for 2019

Sturges Manufacturing Co., Inc. was honored as one of 2019's Best Places to Work in a ceremony in 2019.Sturges Manufacturing Company, Inc. was recently named one of the 2019 Best Companies to Work for in New York. The annual list of the 2019 Best Companies to Work for in New York was created by the New York State Society for Human Resource Management (NYS-SHRM) and Best Companies Group.

This statewide survey and awards program is designed to identify, recognize and honor the best places of employment in New York, benefiting the state’s economy, its workforce and businesses. The 2019 Best Companies to Work for in New York list is made up of 75 companies.

To be considered for participation, companies had to fulfill the following eligibility requirements:

  • Be a for-profit or not-for-profit business or government entity;
  • Be a publicly or privately held business;
  • Have a facility in the state of New York;
  • Have at least 15 employees working in New York; and
  • Must be in business a minimum of one year.

Companies from across the state entered the two-part survey process to determine the Best Companies to Work for in New York. The first part consisted of evaluating each nominated company’s workplace policies, practices, philosophy, systems, and demographics. This part of the process was worth approximately 25% of the total evaluation. The second part consisted of an employee survey to measure the employee experience. This part of the process was worth approximately 75% of the total evaluation. The combined scores determined the top companies and the final rankings. Best Companies Group managed the overall registration and survey process in New York and also analyzed the data and used their expertise to determine the final rankings.

Sturges is excited to announce the company ranked #14 in New York State for small-sized companies with an overall satisfaction rating of 92 percent vs. the survey average of 91% percent.

“The key factor to our success is our team members. At Sturges, we believe team members are a precious asset who deliver the skill and dedication needed to accomplish our goals.  It is a tremendous honor to receive the award knowing that our employees think of Sturges as a great company to work for.  Each year we look forward to receiving the feedback report to guide us to further improvements in the future,” according to Mylissa Deetz, Human Resources Manager at Sturges Manufacturing.   

Sturges Manufacturing, founded in 1909, is a leading producer of engineered webbing and strap assemblies serving the safety, fire protection, as well as a diversified group of original equipment manufacturers.  Sturges operates under an ISO9001:2015 quality management system and maintains an ISO 17025 accredited test laboratory.

For more information on the Best Companies to Work for in NY, visit