Engineering Safety Below the Surface: How Casco Helps Protect U.S. Navy Submariners

When a submarine loses power, the consequences extend far beyond darkness. Critical life‑support systems can fail, allowing carbon dioxide (CO₂) levels to rise rapidly in a sealed environment where breathable air is essential. For decades, the U.S. Navy relied on lithium hydroxide (LiOH) crystals as an emergency solution to scrub CO₂ from the air and generate oxygen.

While effective, the traditional deployment method created a serious safety risk. In emergency situations, submarine personnel were required to manually sprinkle LiOH crystals directly onto the floor. Because lithium hydroxide is highly caustic, direct contact can cause burns to the skin—introducing unnecessary danger at precisely the moment when speed, clarity, and safety matter most.

A Life‑Safety Challenge at Sea

Maintaining a safe atmosphere aboard a submarine is mission‑critical. Under normal conditions, onboard systems continuously purify the air. When those systems fail, emergency procedures must be implemented immediately to protect the crew. The Navy recognized that while LiOH was chemically effective, the method of deployment put sailors at risk and required a safer alternative.

That challenge sparked a collaboration focused on one goal: make a hazardous emergency procedure safer without compromising performance.

A Safer Solution Through Innovation and Partnership

Casco was approached to help solve this problem, and collaboration proved essential. Working alongside Battelle, the world’s largest independent research and development organization, Casco helped design a safer, more practical way to deploy lithium hydroxide during submarine emergencies.

Together, the teams developed a curtain‑style pouch system that safely contains LiOH crystals while still allowing the chemical reaction needed to remove CO₂ from the air. The system uses a specially selected breathable fabric combined with a sealed channel structure. In an emergency, crew members open the curtain and pour the crystals into enclosed channels—eliminating direct contact with the caustic material.

Once filled, the curtain is secured to the submarine wall using wire ties. This design keeps the floor clear, preserves safe passage throughout the vessel, and ensures the LiOH can function efficiently in a confined, high‑pressure environment.

Real‑World Impact That Hits Home

The importance of this innovation goes beyond engineering. During a conversation involving Casco’s company president and a newly graduated high school senior preparing to serve aboard U.S. Navy submarines, the topic of emergency air systems arose. Learning that a safer lithium hydroxide containment system was already in place brought visible relief—an unmistakable reminder that thoughtful design can have a deeply human impact.

Moments like these reinforce why Casco does what it does: delivering products that prioritize safety, reliability, and quality for those who serve.

Continuing the Mission: Adapting to New Challenges

As with many engineered solutions, evolution is necessary. The original material used to manufacture the lithium hydroxide curtains has since been discontinued. In response, Casco engineers are actively working to identify and qualify a replacement material that meets the stringent requirements of the U.S. Navy and the federal government.

This effort involves close collaboration with Navy representatives and David Stewart of Battelle, who has played a key role in coordinating material testing and approvals. Multiple alternative materials are currently in production and undergoing rigorous evaluation to ensure they meet performance, safety, and durability standards.

Once final testing is complete and a Navy‑approved material is selected, Casco plans to manufacture approximately 300 kits to support multiple submarines across the fleet.

A Trusted Government Partner

This project exemplifies Casco’s ability to collaborate on mission‑critical, safety‑oriented solutions. It highlights how Casco’s sewing and sealing expertise, combined with thoughtful material selection and custom design, can significantly reduce risk in hazardous environments.

While this solution was developed for a highly specialized government application, it reflects a broader capability. Casco Manufacturing Solutions serves healthcare, institutional, outdoor, and government markets as a Certified Woman‑Owned Small Business (WOSB), with experience in federal contracting and a Federal Supply Schedule that supports efficient government procurement.

From initial concept through ongoing refinement, Casco remains committed to solving complex problems with precision, quality, and care—both above and below the surface.