Filed Under:
Products
Published on
April 6, 2025
Many industries use soft-sewn cases to hold and carry tools, medical devices, electronics, and other sensitive equipment. The basic business behind them isn't very complicated: select materials that can withstand the rigors of their intended use, design a case that keeps the contents safe and secure, and then sew it up in a manner that can withstand comparable (or better) force and stress than any stress points the case might encounter.
In this post we discuss the materials and manufacturing overview of creating soft bags, cases, straps, holsters, and more.
Selecting the right fabric is the crucial first step in soft case production. The type of material chosen determines, for the most part, the durability, weight, water resistance, and general utility of the soft case. The material used to create soft goods highly depends on the use, planned longevity, and environmental factors it will experience.
Nylon - Renowned for its exceptional durability and resistance to abrasion. Used widely in military and industrial applications.
Polyester - A lightweight, cost-effective fabric that provides a moderate level of durability.
EVA (Ethylene Vinyl Acetate) - Commonly employed as a semi-rigid structure to impart added protection.
Neoprene - A flexible, water-resistant material often utilized for electronics cases.
Leather or Synthetic Leather - Reserved for designs that are premium and consumer-oriented.
Canvas – A durable, thick fibered material often used for military bags or equipment for its strength
The materials that line the insides of cases—be they foam, mesh, or dividers—are chosen based on performance, organizational needs, and the product for the specific use of the case.
Once the materials are selected, a blueprint for the case is drawn up by the designers. This includes:
Determining dimensions and shape based on the product it will hold.
Adding storage compartments, dividers, or straps for better organization.
Selecting closure mechanisms, such as zippers, Velcro, or buckles.
Using CAD software, engineers create a detailed model of the case. A prototype is then made to test functionality and fit. Adjustments are made to ensure that the case is the right balance of protection and usability.
When the design reaches its ultimate form, materials are sliced to the exact measurements required. They are cut using one of several methods:
Die cutting - This method uses a sharp steel blade to cut fabric into precise shapes.
Laser cutting - This process provides superb accuracy for intricate designs and is perfect for larger production runs.
Manual cutting - This method is used when production numbers are low, and for very special cases (which sometimes might also call for these methods).
After cutting comes the prep work for assembly.
The pieces of fabric are stitched together with specialized industrial machines. There are several techniques that ensure durability and performance of the seams:
Lock stitching - This is used to create a strong, tight seam.
Binding tape sewing - This is used to reinforce edges and to prevent fraying.
Box stitching - This is used to securely attach handles and straps in such a way that they can bear weight without coming apart.
For cases that require additional structure, foam padding or EVA inserts are added between layers of fabric before final stitching.
Soft cases often have extra useful features, for example:
• Webbing - For applications that require breathability or an enhanced look.
• Handles and Straps - Added to make carrying more comfortable and convenient.
• Custom Foam Interiors - To create a tailored fit and protect the contents.
• Zippers - With our without locks for added security and to seal the product.
Also, soft cases can have branding features. For example:
• Logos – From embroidery to screen printing or plates and patches, soft sewn branding is easy.
• Special Textures or Designs – Material choice and stitching adds small or large detailed touches.
• Custom Color Scheme – Match your brand or product colors to create a consistent look.
Prior to shipping to customers, a soft case goes through exhaustive quality control tests. This guarantees that:
Durability Testing – Ensures the case holds up to the environments it will be used in. This could include water, temperature, resistance, or friction testing.
Aesthetic – A visual inspection to ensure no seam or stitch is out of compliance with the customers instruction.
Customer Approval – Sample are sent to the customer for approval before the product is produced, ensure what they see is what they get.
The making of soft-sewn cases is a detailed process requiring meticulous material selection, exacting cutting and sewing, and stringent quality control; all in alignment with the customer to ensure the soft-sewn case is exactly as need. For industrial tools, military gear, or medical devices, the steps of this process are designed to ensure that the case offers durability, functionality, and protection.
With Royal Case Company, you get over 40 years of experience and continued improvement, with unmatched service and attention to your project. We offer free in-house sampling to show you are skills and get you case right for you. Call us today to get the right case for your OEM product.
Author: Kelvin Gentry
Kelvin Gentry is the Marketing Director for Royal Case Company Inc. based out of Sherman, TX.
