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, waterproof and 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.

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 going into 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 reduces the time required to finalize the design.

If you have a specific layout in mind you can let us know with a drawing or an email description but we can also propose 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. As a general rule, a minimum of 1" is required all round and 1/2 " to 3/4 " between objects. Allow for a thickness of 1/2" for the base pad on the bottom of the case.

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).

Once we have all the technical information required to proceed with the design process our team of designers will prepare a set of drawings that clearly illustrates 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.

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 the foam meets the initial requirements. Once the prototype has passed our internal QC inspection we will ship you the foam inside the case for review.

Your sales representative will arrange to have the prototype shipped to you for review and approval. If the prototype is to your satisfaction simply sign the provide production approval drawings and we are ready to start production. Occasionally it may take several revisions and/or prototypes to get the fit just right.

Once the foam design is approved we can move into production. There are three different methods we use to manufacture the foam 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. Either a vibrating blade or traditional router bit will be used

Die Cut: Higher volume runs are usually produced using a die(s). The die cutting process allows for a higher rate of production

Waterjet: Low to mid volume runs can be produced using the waterjet process. Waterjet can also allow for very fine details that cannot be produced with a die. Our specialized equipment ensures that every custom foam is produced to a very high level of quality while having the flexibility of multiple processes allows us to offer quick lead times at a very competitive price.

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

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

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