Filed Under:
Products
Published on
April 3, 2025
Protecting equipment, tools, and delicate devices across many industries from the rigors of travel and work demands is essential for your customers, so it’s important to provide them a case that protects their investment. Although a normal 'pilot case' can serve well for many general applications, when one gets into a world with needs that are more specialized and demanding, the types of cases we are going to discuss seem to be the default option. So, what are the considerations that supposedly make these things worth the price? The post follows on from a previous one that emphasized that before considering any of the following factors, we need to take materials and construction into account since these elements affect the case's performance under different conditions.
Before beginning the design process, it's necessary to specify the case's intended usage. Key Questions to Consider:
What will be housed in the case? The dimensions, weight, and delicacy of the equipment factor heavily into material and interior arrangement decisions.
Will the case be employed as a transport medium or as stationary storage? Cases that are taken on the road may require carrying handles, reinforced corners, and other such accents, while those that are going to be set on a workbench may be designed in a way that makes access, not portability, the priority.
What sorts of environmental conditions are we expecting? Extreme temperature, moisture, or dustiness levels will drive sealing and material selections.
Is impact resistance a priority? Military, industrial, and NASA applications often require cases that can take a licking and keep on living.
The case's material defines its strength, heft, and ability to withstand such things as impacts, chemicals, and the kinds of environmental stressors that accumulate over time. Three common hard case materials are:
A lightweight, tough, and impact-resistant material.
Used in injection-molded cases like the ones seen in military, medical, and industrial applications.
A more rigid material than polypropylene, with excellent structural integrity.
Frequently found in cases for tools and protective enclosures.
A corrosion-resistant material with a professional appearance, lightweight yet strong.
Found in aerospace, industrial, and high-end storage cases.
Five other materials may appear in hard case construction, but these three are by far the most common.
The hard case's inside is what allows it to perform the three essential functions of shock absorption, organization, and accessibility. There are many ways to customize the case's interior; four of the main options are discussed below. Because the interior plays such a key role, these options can be considered "shock-absorbent" in that they help ensure delicate equipment survives an unfortunate drop or similar mishap.
Foam Inserts - One way to create an interior that is shock-absorbent and tailored to your equipment is to use foam inserts. This interior option is custom cut to your product and comes in a variety of materials and densities. It’s a great way to cradle your product and create a long-lasting protective interior.
Thermoformed/Vacuum formed Inserts - These interior options are molded around your product to ensure proper fit. While not as sturdy as some insert options given, they are typically single wall plastic leaving a hollow area, they provide an economical and precise fit to keep your product secured in place.
Sewn Dividers - Looking for a more premium fit? Sewn interiors allow a high level of customization using pouches, straps, zippers, colors and more. They are custom designed to include as many features as you need to house product or other accessories.
The way a case closes determines how well it protects whatever is inside from accidental opening, theft, or environmental elements. Here are some common closures and locking mechanisms:
Heavy-duty latches made of either plastic or metal, which keep cases securely shut.
Padlock-compatible holes, which allow use of TSA-approved locks for secure travel.
Valves, found on waterproof and airtight cases, that equalize air pressure, so that case contents aren't "sucked out" or "push[ed] in" when the case is opened.
Locks that are tamper-resistant, for cases in which the contents are too valuable or too sensitive to risk any unauthorized access.
When frequent transportation is necessary, usability can be greatly enhanced through ergonomic and mobility-improving features. Necessary Portability Features:
Ergonomic Handles - For comfortable carrying, even over long distances.
Shoulder Straps or Backpack Straps - Wonderful for when you’re keeping a case light and portable; great for the kind of equipment field professionals and military personnel use.
Rolling Wheels and Telescopic Handles - Better found on heavy-duty or large cases and used in conjunction with a case that is too heavy or cumbersome to carry.
Cases intended for hard use must be tailored to endure the environmental conditions of their intended deployment. Environmental factors to consider include:
Waterproof - Cases using O-ring gaskets offer an IPX-rated, waterproof seal.
Dustproof -Make sure that nothing short of a vacuum can get inside and harm your sensitive electronics.
UV Resistant - Ensure that the case won't degrade in high-sunlight applications.
Chemically and Fire Resistant - These are absolute musts for cases storing hazards of any sort and are equally important in industrial applications.
Following these guidelines will help extend the lifespan and functionality of your case.
Hard cases can be tailored to the needs of businesses and professionals to increase product identifiability and provide branding opportunities. Customization for Branding and Identification: • Custom Colors and Textures: We match your corporate identity. • Screen Printing and Engraving: We add your logos, product details, and riveting statements to cases that are equipped for the rigors of your profession. • Nameplates and Tags: Assist with inventory tracking and add yet another layer of personalization. Branded cases will up your presentation ante and increase product recognition.
Creating a custom hard case necessitates an exacting attention to detail. The materials we use must not only meet the strength and durability necessary to protect our clients’ valuable equipment but also possess aesthetic qualities that allow us to produce striking cases on behalf of our clients. Internal protection must be thoughtfully engineered to ensure that delicate components remain so during shipping and transport. Security, of course, is paramount. And finally, portability: a custom hard case must be easy to use and to carry in whatever environment the client requires.
Author: Kelvin Gentry
Kelvin Gentry is the Marketing Director for Royal Case Company Inc. based out of Sherman, TX.
