Filed Under:
Products
Published on
April 27, 2025
ATA cases are sturdy, impact-resistant, and longest-lasting protective travel solutions for a variety of valuable gear like AV equipment, rigging, musical instruments and more. They are made to withstand the kind of abuse that comes with travel and shipping, yet somehow also manage to look professional and keep a semblance of order inside. That's not an accident. The manufacturing process that goes into an ATA case is directly responsible for the kind of security, organization, and durability that the cases are known for.
Selecting the proper materials to create the desired durability and impact resistance is the all-important first step in the manufacturing of ATA cases. The cases are usually made of a mixture of plywood, aluminum, and foam but also use several other common and uncommon materials. Here are some of the materials used in making ATA cases:
Plywood (⅜” or ½” thick) - A strong, uniform base for the case.
Vinyl or Fiberglass Lamination - Waterproofs the case and adds a little extra layer of damned-if-you-do durability.
Aluminum - A little bit of this extruded around the edges does wonders for the structural integrity of the case.
Steel or Zinc-Coated Ball Corners - Protects the corners of the case, which are prone to hit first and hardest when the case is dropped.
Interiors - Foam, carpet, wood, or mechanical components cut and built to house specific products or equipment.
After the materials have been chosen, the case is custom designed using CAD software, with the following key design considerations:
Dimensions & Shape - Customized to fit specific equipment.
Foam Interior Layout - Tailored to provide secure storage and shock absorption.
Latches & Locking Mechanisms - Selected based on security and ease of access.
Portability Features - Wheels, handles, and stacking designs are incorporated based on transport needs.
When the design is set, the case parts are cut, shaped, and assembled with exactness. The real fun of fabrication happens here. With all the careful planning and design work, it's now time to see the finished product take shape in the shop. Key fabrication steps:
Cutting the plywood panels - CNC machines cut the plywood sheets to size.
Laminating the exterior - We bond ABS plastic or fiberglass to the plywood for a much more durable case.
Attaching aluminum extrusions - We add aluminum reinforcements along the case edges for structural support.
Installing ball corners - Steel ball corners protect against drop damage and impacts.
Mounting latches and hinges - We install heavy-duty hardware to provide secure closure and easy access.
Each Royal Case Company ATA case is built by expert craftsmen in the USA.
An ATA case's interior is as critical as its exterior; it needs to absorb shock, organize, and protect. Common Interior Features:
Custom-Fit Foam - Cut to hold the delicate equipment it secures (cameras, audio gear, medical tools).
Padded Dividers - Ready for the sectioning that's required when organizing storage.
Shock-Resistant Lining - It should be noted that high-density doesn't mean stiff or hard; the lining should be comfy so the case can be hugged tight while being carried.
Mechanical Devices - Built in mechanical options to help with easy display, organization, and use.
Quality control and durability testing are strict and meticulous before an ATA case is sent off to the customer. The following are common quality control tests:
Drop and Impact Testing - The case is subjected to the kind of handling it would endure in the field, plus a bit more, and it must pass this test to attain quality control clearance.
Water and Moisture Resistance Testing - This case must be able to pass through heavy rain, just as a traveler must, the very kind of humidity that could harm electronics in an unsealed case.
Latch and Hinge Durability Testing - This is about the hardware used to open and close the case at either end.
Once the case clears quality control, it moves on to the final assembly and branding stages. Final Touches:
Paint labeling or Screen Printing - For easy identification, the cases get logos, serial numbers, and other labels.
Stacking & Portability Features - Smart design ensures efficient transport and storage.
Final Cleaning & Inspection - Makes sure the case is ready for shipment and immediate use.
Once all that's completed, the ATA case is sent out to customers all over the world.
ATA cases provide transport solutions for maximum durability, security, and protection. What goes into making one?
Material selection - Carefully chosen materials that fulfill several functions simultaneously—from the inner lining that gently cradles delicate equipment to the outer skin that resists rupture—are essential to the case's construction.
Precision fabrication - Errors in the assembly of an ATA case can lead to a malfunction. Why? Because each case is built to exceed performance demands that no ordinary road case would be expected to meet.
Testing - No case would meet ATA standards without passing a battery of tests first.
Customization - Professionals who work in music, medicine, the military, and emergency response come to us for custom ATA cases tailored to their exact specifications.
Questions? Contact us today to learn more.
Author: Kelvin Gentry
Kelvin Gentry is the Marketing Director for Royal Case Company Inc. based out of Sherman, TX.
