The idea for Radius originated from a Caribbean beach in Tortola, developed by architects Kevin Foley and James O'Halloran. The company aims to revolutionize personal daily care appliances, particularly toothbrushes, for billions of people worldwide. In the early 19th century, the family-owned, women-led manufacturing company Radius was established in a 20,000-square-foot waste feed processing plant in an Amish village in Pennsylvania. After O'Halloran retired, Kevin's daughter, Saskia Foley, took over as CEO in 2011. She has also been involved in assembly production during summers and has served as Vice President of Sales for many years. Her father remains the president and research and design consultant.
Radius designs and manufactures its high-energy solar products in Kutztown, PA. Each product undergoes manual inspection to ensure a lifetime guarantee. The company's unique ergonomic Toothbrush features a 5,500-fine nylon brush head—about two-thirds the thickness of Oral B40, with five times the original hair count. It is available in both left- and right-handed versions. The body is made of fiber, and the brush head is oval-shaped to reduce gum pressure. According to the company, this handshake concept is new to the dental field and not suitable for small tank toothbrushes sold or introduced in China. Although still developing, the design has already begun to take shape. Other brands have tried to copy the idea but have never fully implemented it.
The evolution of packaging began in 1983 when Radius used simple folding cartons. Customers often opened the trays to check the color and shape of the toothbrush, prompting a switch to transparent plastic folding packages. However, these became plastic waste once opened. In 1992, the company started using plastic packaging that could be reused as travel containers. Despite their durability, customers accumulated multiple sets, and transportation of plastic was energy-intensive. In 2005, Radius explored lighter and plant-based packaging alternatives, aiming to reduce freight volume. This led to the development of "fake clamshell" packaging, with a lightweight front and recyclable cardboard back.
Previously, Radius used transparent thermoformed film for blister packs, made from 50% recyclable PET bottles. All toothbrush series, from children to adults, used this package form. Now, the Baby and Totz series are their biggest sellers. CEO Saskia Foley stated, “Although this is good, there's still too much plastic.†She emphasized the need for eco-plastics, such as recycled PET, without custom molds and a less plastic-like appearance. This led to re-evaluation, with Kevin exploring ways to make plastics in a specific shape with less material. Eventually, they chose blister packs.
The "shell" blister is a variation of hard shell packaging. Instead of sealing between two heat-seal sheets, it seals the filled blister onto a cardboard sleeve. The label on the back can be pressed while retaining the bulb shape. Recently, Radius switched to a new sleeve supplier, Transparent Container, allowing automatic sealing. Labels are now sealed on a roller-type heat sealing system. For more details, visit pdlinks.com/Radius.
Changing suppliers solved some issues. The new packaging design adds a third dimension on both sides, facilitating upright placement during retail displays. Additional marketing information is now printed on the packaging, including the website, slogan, and toothbrush type. Previous suppliers couldn’t produce pre-teared sleeves, requiring manual tearing. Switching to Transparent Container eliminated this step. “Finding suppliers that simplify the process without needing three tears is key,†said Foley.
Radius’s single-process solution involves working with one supplier who handles both sleeve and blister manufacturing. This streamlines production and improves coordination with suppliers, ensuring consistent quality and appearance. “The more we streamline, the better it is for us,†explained Foley. “Consumers see beautifully made, sealed, and consistent-looking products.â€
In 2023, Radius broke the record of 3.1 million toothbrushes, travel kits, and replaceable brush heads. During the holiday season, 40% of annual sales were achieved, totaling 4.1 million molded products. Over the past three years, the company has grown at an annual rate of over 50%. Their product line expanded from original brush heads to include dental floss and travel kits. Martha Stewart Living selected Radius as a finalist in the Made in America competition, highlighting its innovation and quality. For more details, visit the official website.
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