Filed Under:
Manufacturing
Published on
December 9, 2025
Your mission-critical equipment is constantly at risk when in transit. According to the Federal Motor Carrier Society, in 2021, a staggering 5,904 large trucks were involved in fatal crashes, highlighting the dangers on the road. Protecting your assets is an operational necessity, not a luxury.
At Royal Case Company, we understand these risks and have perfected a nine-stage workflow to create the ultimate protection for your gear. Our process transforms a concept into an ATA-compliant fortress, ensuring your assets are safe and secure.
This is your inside look at how we build industry-leading custom road cases from the ground up.
Every world-class road case begins with a detailed conversation to understand your project's specific demands. We analyze environmental threats, transport methods, and critical compliance standards.
Our thorough assessment ensures the final design offers ideal protection when transporting special and delicate equipment. This commitment to adaptability ensures each case is custom-engineered to protect your gear.
This foundational step guarantees the final product performs flawlessly under pressure. We collect key data points to inform the design, including:
Our engineering team translates your requirements into a precise digital drawing using advanced 3D CAD software. We model every component and all parts, from the external shell and its reinforcements to the intricate internal foam cushioning.
This process includes Finite Element Analysis (FEA) to simulate drops, impacts, and stress, ensuring the design withstands real-world forces before production. Our specialists collaborate to plan tolerances and ensure every latch, hinge, caster board, extrusion, and other hardware works in perfect harmony.
This rigorous, data-backed process turns your protective needs into a performance-verified design ready for prototyping. Here are the design variables and their performance impacts that guide our engineering decisions:
A superior design requires premium, task-specific quality parts. Whether you are looking for a partner to help you build your own road case or need a specialized flight case for air travel, we have the perfect solution for you.
Our custom hard cases are built with laminated plywood panels made from high-grade birch for its strength-to-weight ratio, laminated with tough, scratch-resistant ABS plastics. The frame features interlocking aluminum extrusions, ball corners, and steel rivets for immense structural rigidity, ensuring maximum durability.
Every piece of hardware, from recessed butterfly latches to heavy-duty wheels, is chosen for reliability and ergonomic transport. While we specialize in rugged exteriors, we also produce lighter solutions like a custom EVA case or flexible silicone cases for different applications.
Before full production, we bridge the gap between digital design and physical reality with rapid prototyping. Using in-house CNC machinery, we create exact-specification panels for a "test-fit day."
This allows you to bring your equipment to our facility to ensure a perfect fit, check handling, and validate the overall design. It’s a crucial step as it mitigates risk and allows for fine-tuning before scaling up production.
During this phase, we also conduct preliminary ATA drop and impact checks to confirm that our engineering and material choices meet compliance standards.
With an approved prototype, we move to full-scale production where precision craftsmanship meets automation. The process begins with router-cut wood panels, often using dado joints for superior strength. High-pressure lamination bonds the ABS outer layer to the birch core, creating a rugged, laminated shell.
Our skilled technicians then assemble the cases using power tools, industrial glue, and carefully placed screws and t nuts, while leveraging automated machinery for speed and consistency. This hybrid approach ensures the nuanced touch of a craftsman for critical joints and the speed of automation for hardware installation.
The exterior of a road case is only half the story. True protection comes from a perfectly engineered interior. Using 3D scans of your equipment, we design and cut precision foam inserts that cradle every contour.
This material provides maximum shock absorption and prevents movement during transit, which is critical given that transportation workers experience most injuries from moving materials. We use water-jet cutters, die-cutters, or CNC routers depending on the application's complexity.
We often use multi-density foam laminations for optimal impact absorption and structural support. Our capabilities extend to creating a custom soft case interior with industrial sewing for accessories, pouches, and organizers within the lid.
Our commitment to reliability is validated through a rigorous quality control and testing regimen. Before any case ships, it undergoes checks for fastener torque, hinge and latch durability, and wheel performance under load.
Every flight case and own road case is designed to meet or exceed ATA Spec 300 Category I, the airline industry’s highest standard for reusable containers. For military and industrial clients, we also test against MIL-STD-810 standards. Our compliance checklist includes:
The final stage focuses on polish, professionalism, and asset management. We offer a full suite of finishing options, including multi-color silk-screened logos, custom laminates, and stenciling to represent your brand.
Once finished, each road case is meticulously packaged for transit using protective wraps to prevent scuffs. For sensitive equipment, we can include moisture indicators. We also offer durable, recyclable eco-wraps for clients with sustainability goals.
A perfectly built road case is useless if it doesn’t arrive on time and on budget. Royal Case Company operates a global manufacturing and distribution network to reduce freight costs and shorten delivery timelines.
Our warehousing facilities offer global logistics services, including international shipping and freight coordination. Whether you need a white-glove delivery, a bulk shipment, or a direct drop-ship to an event, our logistics team manages the entire process.
We handle the complexities of global shipping so you can focus on your mission with confidence.
This nine-stage journey, from initial design to final delivery, is how we fulfill our “Designed. Developed. Delivered.” promise. If you were curious about building customized cases, our expertise goes beyond a few cases. With detailed assembly information, we guide clients through every aspect, from design consultation to finishing touches.
By mastering every step of the construction process, from circular saw and miter saw operations to selecting the best quality parts, we create more than just a box or your own road case with steel ball corners. Through expert craftsmanship, we engineer confidence.
Whether you need standard cases or fully custom-built cases, our process guarantees an ATA-compliant protective solution. Each case utilizes premium-quality parts and sturdy caster boards for optimal performance.
This level of detail is essential for touring musicians, broadcast engineers, and military operators, where failure is not an option. You have seen the process, precision, and passion that go into every case we build.
Don't risk your valuable equipment with inadequate protection. Protect your mission-critical assets with Royal Case Company, a partner you can trust, with industry-leading expertise.
At Royal Case, we are committed to meeting your compliance needs. To ensure accuracy and satisfaction, all compliance requirements must be communicated to us before an order is placed. We can manufacture to nearly any standard, but those standards must be stated in writing prior to production. Please note that compliance not disclosed in advance cannot be guaranteed.
