1. Select your case

Case selection is the first step in the custom foam design process. Depending on your project requirements​,​ you may need a case that’s tough ​and​ waterproof with a lifetime warranty​—​NANUK is the case you need. Looking for something stylish and affordable? Our Designer series may be the way to go. Once the case is chosen​,​ the final step in the selection process is to decide on a color.

Select your case
Send us Your Drawings and Components

2. Send us your drawings and components

To begin the design process we require drawings​,​ in either 2D or 3D format​,​ that accurately represent the shape and size of the items that will be ​placed inside​ the case. When possible​,​ we prefer to have the components shipped to us prior to starting the design process. This allows us to physically test the fit of the components in the case and ​it​ reduces the time required to finalize the design.

3. Customer indicates preferred case layout

If you have a specific layout in mind​, you can let us know with a drawing or an email description​,​ but we can also ​suggest​ the most effective layout based on your requirements. Occasionally during this process​,​ we will need to move to another case size in order to allow for enough foam to protect your equipment.

Customer indicates preferred case layout
Foam Selection

4. Foam selection

Plasticase offers a variety of different types of foam for your project. Foam selection is usually dictated by three factors: the level of protection required, aesthetic appeal​,​ and price. The foams that we typically use fall under three material families​:​ polyurethane (PUF), polyethylene (PEF)​,​ and Ethylene-Vinyl Acetate (EVA).

5. Develop drawings for customer review

Once we have all the technical information required to proceed with the design process​,​ our team of designers will prepare a set of drawings ​to​ clearly illustrate the layout of your equipment ​inside​ the case. These drawings will also indicate all engineering details required to manufacture the foam. Your representative will send you the drawings for preliminary approval to proceed to the prototype phase.

Develop Drawings for Customer Review
Prototype Production

6. Prototype production

Once the drawings have been reviewed and accepted by the customer​,​ we will produce a prototype to confirm fit and function of the design. Our engineering department will review the prototype to confirm ​that​ the foam meets the initial requirements. Once the prototype has passed our internal QC inspection​,​ we will ship the foam ​to you​ inside the case for review.

7. Customer approval

Your ​S​ales ​R​epresentative will arrange to have the prototype shipped to you for review and approval. If the prototype is to your satisfaction​,​ simply sign the provide​d​ production approval drawings ​in order to proceed to the start of​ production. Occasionally​,​ it may take several revisions and/or prototypes to get the proper​ fit.

Customer Approval

8. Production

Once the foam design is approved we can move ​towards​ production. ​We employ​ three different methods ​of foam manufacturing, depending on the requirements of the project.

  • Once the foam design is approved we can move ​towards​ production. ​We employ​ three different methods ​of foam manufacturing, depending on the requirements of the project.
  • CNC Router: Low-volume runs or designs that require multiple cavity depths will usually be produced using the CNC method by using a vibrating blade or traditional router bit.
  • Die Cut: Higher volume runs are usually produced using a die(s). The die cutting process allows for a higher rate of production.

9. Quality control

The foam production process is constantly monitored to ensure a consistent quality throughout the production cycle. Important elements ​that are verified​ during the QC process include​:​ material integrity, cavity profiles​,​ and depths​,​ along with fit ​within​ the case. Our strict document control process ensures that all unique​ specifications to your project are clearly indicated to ensure ​that​ each production meets your expectations.

Quality control
Final Case Assembly

10. Final case assembly

After the foam has received its final QC approval​,​ it can ​proceed​ to the final assembly stage. Depending on your requirements​,​ the foam can either be glued ​inside​ the case or left loose. A final QC check is performed to make sure ​that​ the case meets your requirements and is then ready to be shipped to your door.

11. Finished product

Whether you need ​10 or 10,000 cases​,​ Plasticase has the expertise to deliver a complete case solution on time and on budget.

Finished Product