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Shortly after arriving as medical director at Philips four years ago, Hisham Elzayat faced an internal crisis that threatened one of the world’s largest makers of breathing machines. The longtime heart surgeon had pored over a spate of complaints about the company's best-selling devices, which were filled with an industrial foam capable of breaking down into tiny particles and fumes. When inhaled, the toxic material could move through the nose and sinus cavity and into the lungs, a stealth intruder that threatened incalculable harm. After meeting with a top Philips biosafety engineer who also expressed concerns, the 46-year-old doctor said he had seen enough. In June 2020, he pushed to stop all shipping of the devices from the company's factories near Pittsburgh and pressed to meet with one of the company's most powerful executives to take on what he called an unfolding emergency. "I have made my safety concerns known," he recalled in an internal complaint. But the company turned down his request to halt the deliveries and instead ratcheted up sales of its CPAPs and ventilators during the throes of the pandemic while Philips took in hundreds of millions of dollars in revenue. Dr. Elzayat’s internal battle to pull the machines off the shelves is detailed in hundreds of pages of company emails, text messages and reports that have been turned over to federal prosecutors as part of a criminal investigation of the leadership of the company, according to sources with direct knowledge of the probe. The confidential documents, which have been obtained by the Post-Gazette, show for the first time the surgeon was among nearly a dozen Philips engineers and others who pushed the company to warn patients about the dangers of the foam before Philips removed millions of the devices from the market in a recall in June 2021 and to later stop the company from downplaying the risks.

Inside the raging battle at Philips: Internal fights and resignations over dangerous breathing machines

Inside the raging battle at Philips: Internal fights and resignations over dangerous breathing machines

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