“You do all THAT?!”
We hear it every time someone sees what actually happens inside our facilities.
For more than 70 years, we’ve been proud to do something increasingly rare in today’s global market: we manufacture all our products right here in America. In an industry where many companies outsource large portions of their production, we continue to design, engineer, test, and build nearly everything in-house at our two U.S. facilities.
Why? Because our customers depend on us – firefighters, police officers, medical professionals, tow truck drivers, DOT teams, and so many others on the front lines. When the stakes are this high, quality, reliability, and rapid support aren’t optional - they’re mission-critical.
Here’s a closer look at the questions we hear most about our American manufacturing process and why it matters.
Yes. Nearly every Whelen product is fully Manufactured in America - not just assembled. We design, engineer, mold, machine, solder, test, and assemble everything at our Chester, CT, and Charlestown, NH facilities. No overseas outsourcing.
We prioritize vertical integration, which means we control the entire process:
- Product design and engineering
- Printed Circuit Board (PCB) manufacturing
- Optics development
- Injection molding
- CNC machining
- Software and firmware development
- Environmental, vibration, and optical testing
- Final assembly, packaging, and shipping
This level of control ensures unmatched quality and reliability.
We manufacture our own lights from start to finish, and we manufacture the components that go into them – we even make the tools that manufacture the components that go into each light! Our workforce of over 1,800 employees includes the largest design team in the emergency lighting industry, along with engineers, machinists, technicians, and operators who work together to ensure every product that leaves our facilities meets the highest standards. Many of our team members are former or active first responders themselves, bringing firsthand experience and a deep understanding of the real-world demands our products must withstand.
American-made products provide advantages first responders can rely on:
- Higher quality control and durability
- Faster product development and innovation
- More reliable supply chains
- Engineering designed for real-world field conditions
- Rigorous in-house testing that exceeds industry standards
- Direct support from the people who built the product
For emergency vehicles, this means equipment that performs when it matters most. It’s not just a manufacturing choice—it’s a commitment to safety and reliability.
More than most people realize. From raw materials to finished products, everything happens within our walls, giving us complete control over quality and consistency.
Absolutely. We build:
- Printed circuit boards (PCBs)
- LEDs and optical components
- Injection-molded housings
- Aluminum extrusions
- Wiring, cables, and harnesses
Primary components shouldn’t be outsourced - we make them where we build the product.
Yes. Every product undergoes rigorous in-house testing, including:
- High/low temperature cycling
- Dust and water ingress testing
- Vibration testing
- UV and environmental testing
- Optical performance validation
If it bears the Whelen name, it has been tested to the highest standards.
Whelen is known for building some of the most durable, dependable emergency vehicle lights in the world. Our vertically integrated, American manufacturing model ensures long-term reliability that first responders can count on.
Not necessarily. Vertical manufacturing reduces outsourcing and supply chain risks. While the upfront cost may be higher than low-cost imports, Whelen products are built to last—resulting in a lower lifetime cost.
Yes. American manufacturing strengthens local economies, and we’re proud to contribute.
Whelen supports thousands of families through:
- Long-term career opportunities
- Skilled trades and technical jobs
- Training and development programs
- Community involvement and partnerships – learn more about how Whelen Gives Back
Yes. Whelen Engineering remains family-owned and operated, carrying forward the values established in 1952.
Absolutely. American manufacturing is part of who we are. As we grow into new technologies and markets, our commitment remains the same:
Designed, tested, and built in America.
Why is Whelen Trusted to Protect First Responders?
At Whelen, “Manufactured in America” isn’t a slogan - it’s a promise. Every product we build is created with one mission in mind: protecting those who protect us. By keeping our process in the U.S., we ensure unmatched quality, faster innovation, tighter control, and genuine accountability. It’s why we’ve been trusted for over 70 years, and why we’ll continue manufacturing right here at home for decades to come.
We design it.
We engineer it.
We build it.
We test it.
We ship it.
All here in America.
Yeah, we do all that.
Click HERE to learn more about why first responders choose Whelen and how our American-made products help keep communities safe.