Manufacturing Process
How will it be made?
The mold of each half of the bag will be made (male mold) from there, a thin plastic will be vacuum formed to the mold. Excess plastic will be removed after forming is complete. The process can be seen in the below on how plastic hard shells are made for suitcases. The outcome can also be achieved through injection molding. Inner containers will also be vacuum formed or injection molded as well.
After this process, the fabric will be stitched, stapled, and/or glued onto the plastic. The custom foam inserts will be constructed out of CNC’d EVA or polyurethane foam to the desired shape of the equipment. Inner containers to house the custom foam inserts will be injection molded out of low impact polystyrene.
Strap will be assembled and attached the body after it is finished.
Materials
- Dark grey Neoprene fabric
- Nylon zippers
- EVA or closed cell anti-static polyethylene (inside)
- Optional — Convoluted foam
- 3D spacer material
- Low impact polystyrene (inner container)
- High impact polystyrene (outer container)
BENEFITS OF CUSTOM FOAM INSERTS
(sourced from https://www.productioncase.com/custom-foam-inserts)
While they cost a little more, custom foam inserts offer much better value:
- Saves money over time. Custom foam inserts last the lifetime of your gear. Pick N Pluck foam, while cheaper, has to be replaced every few years because it loses density and yellows.
- Looks much more professional. Nothing matches the precision and custom fit of our CNC-cut foam inserts. No matter how good your manual dexterity is, the cubed cuts of Pick and Pluck or cubed foam mean the end result just isn’t as precise.
- Fits more gear and protects it better. Achieve CNC precision using your own design files or take full advantage of Production Case Company’s in-house design team. Using SolidWorks 3D (along with additional software provided by our foam suppliers), we are able to determine the most suitable layouts based on the fragility of your equipment.
- Different foam options available. Depending on your needs, you can choose from a variety of foams including Plastazote (cross-linked polyethylene), closed cell anti-static polyethylene, and regular closed cell polyethylene. We even have a variety of colours available on request.
- Case foam and beyond. Don’t forget that custom foam inserts are not limited to cases. They can be used in soft-sided bags, backpacks, CAVE drawers, and a nearly endless list of other applications.
- One-time template design fee. Unlike many other case companies, we don’t charge for design if you ever need a copy of your insert.
