We have not experienced this problem to date in our labs.
We use the Encon 500 Goggle (chemical splash goggle) that has a cloth covering all of the way around the parts of the goggles that touch the face. The students/researchers like this style because it is much more comfortable to wear for hours at a time.
This might work for your student.
Disclaimer: I have no connection to or affiliation with Encon or any other goggle manufacturer.
Perhaps someone has experience with this.
We have a student in general chem lab who appears to be sensitive to the materials in his lab goggles. His face was red and showed raised bumps and he reported the contact was very painful after just short time. We tried careful washing of goggles and a pair from another maker, with very similar results.
Today I'm going to give him a pair of safety glasses and a full-face shield to use while we pursue this question. I plan to let him take several pairs of different goggles with him and try them - perhaps an hour at a time - at home to see if he can find something useful.
Is there anything we can apply to the flange material to isolate it from skin? Any and all suggestions are welcome!