Custom Cases

Case Study:Color Test Kit

The Challenge

A leading company in color control systems came to Source to redesign their color test kit. The existing case was wood and had four wood trays holding the color chips.

The Response

The client wanted a bold new look to bring their case into the 21st century - our aluminum case provided the desired look. Molded plastic trays with clear lids were proposed instead of the wood trays, which would allow the color chips to be seen when the case is open.

The Solution and Results

Source designed and manufactured a low profile smooth aluminum case with chrome hardware. A four color label is attached to the front of the case. The base of the case is lined with EVA polyethylene foam while charcoal polyurethane foam in the lid secures the thermoformed color chip trays. Each tray is thermoformed from black matte HIPS, with a clear lid allowing colors to be viewed while secure within the tray. The base and lid of the tray are CNC cut to provide a clean, smooth edge. CNC cutting increases individual unit prices, but eliminates the necessity for additional tooling. The color chips are arranged in color sequence in the trays, covered and placed into the carry case.

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Case Study:Lean Manufacturing: Tool Control Service Case

The Challenge

A Silicon Valley customer who often works in “clean rooms” was looking for a tool control solution that would allow them to organize and inventory service instruments in an efficient manner without compromising the sterile environment.

The Response

The client wanted a case that segmented tools into service categories so that they could survey the instruments quickly and eliminate/remove unnecessary items for each job. Our ATA SpectraCase provided the right fit for their organizational requirements.

The Solution and Results

Our customized project not only eliminated the risk of time, manpower, and expenses lost by disorganization, but also directly contributed to the client’s lean manufacturing initiative: The customer now uses our custom-made ATA SpectraCases with trays organized into one week, one month, six month, and one year installments to organize and control the tools they need to service machines that produce microchips. They simply swap out the interchangeable trays quickly and efficiently prior to each service call, allowing for on-the-spot inventory and a proactive approach to the task at hand. All of the foam is anti-static and is cut with a water-jet to eliminate dust and

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Case Study:Temperature Controlled Shipping Case

The Challenge

A world-renowned beverage company required a custom solution for transporting liquids from far-off, sometimes Third-World nations, to testing facilities on all corners of the globe. When plastic corrugated shipping containers were used, the bottles shattered, the boxes buckled, and unpredictable temperature fluctuations easily overwhelmed the packages.

The Response

Drawing upon our experience with the medical industry, we designed a budget-conscious soft-side case that could handle the heavy—75 pounds—but sensitive payload and maintain a critical temperature range for sometimes week-long stretches.

The Solution

We designed a soft-side case with a top-loading tray insert constructed of expanded polypropylene foam engineered to increase air flow. Gel packs were inserted into the case walls. We customized the insert to protect the payload, while allowing the temperature to be maintained within the critical tolerance. We built the cases of ballistic nylon strong enough to withstand world-wide travel, handling, and environmental fluctuations. The outer, rectangular case was strengthened with firm polyethylene foam sewn into the lining of waterproof nylon that was added to keep the cold air inside. Molded plastic corners were also attached to the exterior to maintain shape and ruggedize the solution.

For ease of handling, we added recessed inline-skate wheels doubled up to support the heavy payload, and a handle with an ergonomic rubber grip for comfort. The final addition of document pouches and silk-screened branding and handling information established these cases as the optimal packaging solution for the client's needs.

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Case Study:Medical Device Instrument Case

The Challenge

A California-based spinal company relied on flimsy corrugated packaging and commercially-produced dunnage to protect their anatomically-driven instrumentation. They came to Cases By Source to explore more effective alternatives and, in the course of sending their equipment for measurement, experienced first-hand proof of their need for cases: The tools were damaged in transit.

The Response

To protect the client’s sensitive equipment, we suggested a durable but portable case that would guarantee protection and still offer the aesthetics of a sales demo kit. The Pelican 1510 Carry-On Case pairs durable, lightweight construction with a travel-friendly design that meets FAA carry-on size regulations—a perfect solution for this client’s needs.

The Solution

Using our sophisticated structural design tools, we measured each piece of equipment in order to determine the most sensible layout for the custom interior. We then created 3D computer models of the instruments and proposed interior to provide the customer with a quick snapshot of the case before production commenced. For this client, we fabricated a closed-cell cross-linked, routed-foam custom insert to secure the items and display them in an efficient order inside the watertight, crushproof and dustproof case. This foam is available in a variety of densities with rich color saturations. For brand recognition and informational purposes, we added a scratchproof, personalized label to the exterior and a literature pouch was secured in the lid.

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Case Study:Consumer Electronics OEM Presentation Case

The Challenge

A top U.S. manufacturer of technological upgrades for office automation equipment and digital devices came to Source looking for protective packaging that would also serve as a marketing vehicle to help the equipment stand out in the technology superstores.

The Response

Focusing on the client’s need for a lightweight, attractive and protective case, we suggested one of our versatile presentation cases: the EuroCase. Sophisticated, sleek, and minimalist in design, the EuroCase line offers cost-effective options for showcasing and safeguarding your promotional items, tools, writing instruments, pens, eyewear, cosmetics, personal care goods, hearing aids and other consumer, medical and industrial products.

The Solution

We fitted the EuroCase with customized vacuum-formed inserts in the lid and base and added a foam pad with cavities cut specifically for the device and its accessories. (The foam pad adds the benefit of reusability of the vacuum-formed tray as new products are introduced in the company’s ever-evolving product line.) The case's exterior was layered with SoftTouch material for a more luxurious feel and elegant appearance; brand recognition was achieved via silk screening of the company’s recognizable logo in the lid.

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Case Study:Booth in a Box Trade Show Case

The Challenge

Tired of waiting after trade shows for our shipping crates, and observing trade show exhibitors’ poor packing habits and insufficient product protection inspired us to create a better solution for clients who needed a more efficient method of transport for displays and merchandise.

The Response

Inspired by cases we've made for the military—the ones that allow our troops to set up impromptu workstations and communication posts in the field—we designed a case that not only functions as a shipping container, but also as convertible exhibit fixtures.

The Solution

For a recent trade show, we packed a 10’ x 10’ booth’s contents in two of our new 48” x 28” x 30” Booth in a Box trade show cases. We designed the case lids to transform into tables, placed them next to the bases, and draped them to make standard 8’ tables. We used the 14.39 cubic feet—per case—of interior storage space for ancillary literature, coats, tools, and other non-essentials. And while we watched our fellow exhibitors inventory their freight and battle "popcorn," bubble wrap, packing tape, and banged-up corrugated containers, we simply removed the protective plastic wrap from our cases’ exteriors, lifted the lids, assembled the tables, and unpacked and placed our materials. All in less than half the time it took other exhibitors to set up the same size booths. At the end of the trade show, we packed the cases, folded down the table legs into the lid, placed the lids on the cases, and left for the airport…back home an entire day early.

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Case Study:Military Camera System Case

The Challenge

A specialist on active duty for the National Guard Security Force Platoon, wanted to custom build a “Combat Crewman Camera System” for mounting on armored military tactical vehicles and use in various missions and training procedures. He came to us with a napkin sketch and a fixed budget.

The Response

We chose the watertight, crushproof and dustproof Pelican 1490 for its durable construction and locking latches that would ensure a tight closure during transit and not disturb the top-mounted cameras. We also designed a custom foam interior shaped to secure the many components of the client’s creative AV system.

The Solution

The project was a collaborative effort: We engineered the custom foam interior to meet the client’s specifications for the delicate audio and visual components. He did the rest: He mounted multiple XLR connectors on the case and added handles for immobilization during transit and to allow him to open the case without disturbing the camera positions. He also installed several camera pedestal mounts on the case for maximum visibility at a wide range of angles and added other modifications to protect the case from moisture.

To complete the system, the client purchased an Otter Waterproof Case (OC-1000) and converted it into an SD card holder. He also customized a Pelican 1400 (PC-1400) for use as a support case. It stores the rest of the camera system parts, including the mounting brackets, the Otter case with the SD cards, and the camera pedestal extension mounts.

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Case Study:Aluminum Tool Control Case

The Challenge

Our Internet presence inspired an Amsterdam-based lighting and special effects company to contact us about customized tool cases for use on one of Europe’s largest cruise lines. The customer had been using boxes to tote their delicate instrumentation. What they needed was a dedicated line of tool cases — 250 per year to be exact — to organize their maintenance tools for portability and efficiency.

The Response

The client had already reviewed our product lines and expressed interest in our Aluminum Cases, specifically the Alumiwrap offerings. The beauty of Alumiwrap cases is that they are a custom solution, always designed to the customer’s specifications.

The Solution

The client wanted an “emergency yellow” case with black hardware, including key latches, a strong handle, a specific size case to fit into a special compartment, and lid-stays for easy inventory and retrieval. Based on designs provided by the client, we manufactured an Alumiwrap case (can be customized to a wide variety of sizes easily) to their requirements, and designed three foam inserts, each of which required detailed water jet cutting—the best option for such intricate, precise work. The three HDPE lift out inserts were secured inside the case for easy accessibility, efficient organization, and quick inventory and tool control.

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Case Study:Aircraft Brake Case

The Challenge

A leading aerospace company approached Source looking for a reusable solution for transporting 70-pound airplane brakes. Their previous shipping solution consisted of stray, makeshift, and leftover boxes with spray-in foam.

The Response

The client wanted a case that would not only secure and protect the delicate but weighty equipment, but one that would also reinforce corporate identification. Our ATA SpectraCase with a custom foam insert provided the durability and customization they sought.

The Solution

We designed a custom-fabricated ATA Case with plywood laminated to ABS. The case features spring-loaded recessed handles, a fully removable lid for easier lifting and full access to the brakes, reinforced corners for protection during the shipping cycle, a stackable design for convenient storage and transport, and a silk-screened logo and custom color ABS panels for brand identification and reinforcement. The interior was engineered with durable polyethylene foam ergonomically designed with four cutouts that allow for two-person access to the weighty and sensitive materials. At the client’s request, we also added an instructional label on the lid’s interior and affixed it to the foam with an aggressive adhesive to withstand handling.

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Case Study:Spinal Implant Sales Case

The Challenge

A client’s sales team was tasked with presenting to the time-starved medical community an array of complex, fragile spinal implants designed for intricate, life-altering surgeries. The gym bags and cardboard boxes the sales force had previously been using consumed valuable time during visits with doctors; the packages were clumsy and unprofessional, and made quick inventory impossible. The client challenged Source to design a protective presentation case solution that would be as compelling as the product — and as efficient as the doctors needed the pitch to be.

The Response

We wanted to help our client build a professional and well-thought-out presentation mechanism—one in which the parts would be protected and easily accessible, and one that would also help make wise use of the limited time the sales consultants had with healthcare professionals. Custom soft-sided cases provide an attractive, versatile, and lightweight option for presentation, organization, and protection of valuable merchandise. They are perfect for sales demonstrations and can be fitted with a number of value-added options.

The Solution

We produced a padded canvas, cloth bound, soft-sided case with three-color embroidered branding, metal-reinforced carrying handles, and a removable shoulder strap with adjustable hardware and metal snap hooks. The inside lid boasted a clear vinyl pocket stitched to form two separate display sections with zipper closures. A removable cross-linked polyethylene foam tray was fitted into the bottom of the case, with 36 compartments of two different sizes for product organization. Taking into account the delicate nature of the company’s products, we designed the tray with a step so that products would be flush with the top level of the step to ensure protection from impact and also easily accessed during a demonstration. View Other Related Case Studies

Case Study:Dental Display Case

The Challenge

Representatives from a well-respected dental company found Source’s exhibit at an industry trade show. They were looking to develop an updated, dynamic and sophisticated presentation for their traditional instrumentation. The innovative tools and accessories they brought to the exhibition had been presented on a sheath of black velvet draped over a flat surface; the display didn’t make the impact they were aiming for, nor did it highlight the time-honored company’s achievements.

The Response

Considering the client’s aesthetic and functional needs, we recommended a modular system of custom wood cases outfitted with foam inserts to highlight their products’ style and diversity. Cases By Source’s wood cases have a sophisticated and polished look that provides an excellent solution for a wide range of products. The cases not only make an elegant, reusable presentation, but also offer organization and protection. Custom interiors are fabricated from wood, plastic, fabric or foam. Logos can be silk screened or laser burned, and interiors can be customized from routed wood or die-cut foam, or lined with satin or velvet.

The Solution

The client sent us tools for measurement and a set of marked photographs and layout instructions to ensure the most professionally sensible arrangement in the case’s interior. The tools were separated into three categories—slow, high speed, and accessories— each of which needed its own case. We modeled the solutions in our 3-D CAD design software, and then manufactured a series of maple wood cases with a cherry stain and lacquered finish. The top edge of the case was routed for a lift-off lid that fits into the recess, and the interior was customized with a die-cut cross-linked foam insert. Each cavity was layered to a carefully measured height so all components would rest on the same level, and we also added holes in the bottom for dowels, enabling the client to tilt the displays for better viewing angles and a more dynamic presentation. View Other Related Case Studies

Case Study:Firearms Manufacturer Plastic Case

The Challenge

When their original case supplier went out of business, a manufacturer approached Source with the challenge of duplicating their existing case on a firm budget, with only a two-week lead time. Without a case, the client’s production would grind to a halt; customer dissatisfaction would be unavoidable and the financial impact would be crippling.

The Response

A longer-lead time would have allowed our sales engineers to design a custom foam interior, a specialty at Source. However, the ticking clock mandated an alternate approach: We did a thorough audit of the existing case and presented the customer with an educated breakdown of foam-filled, protective stock case solutions.

The Solution

Our large selection of stock cases made it easy to provide a solution that was almost identical to the customer’s original case. We shipped a prototype to the customer via overnight mail and received an order the following morning for 2500 units. Within a few days the customer’s cases were delivered—on time, within budget and without disruption or financial impact. Our approach to this emergent situation impressed the clients and inspired them to place a blanket order (with monthly releases) for the cases. We now also provide the client with a branded vinyl label for application to the case prior to shipping from the factory. Giving their logo this heightened visibility has improved the company’s brand recall and customer recognition in the marketplace. View Other Related Case Studies

Case Study:Space Pen Case

The Challenge

A well-known aerospace company wanted to transform the pen they designed for astronauts into a high-end consumer product. They knew the solution was largely dependent on the instrument’s package design and presentation, but the company was soured by the long and inconsistent lead times of their previous case supplier. Looking for a better experience, the client came to Source looking for something sleek, stylized and cost efficient. Standardization was also critical because their intention was to broaden their product line and enhance brand recall.

The Response

Source’s design team met with the customer to offer new and previously unexplored ideas and to ensure the solution would meet the client’s objectives. Using sample pens and literature for inspiration our designers drafted multiple options for the client—some completely custom, others pairing stock cases with custom inserts.

The Solution

Source took an outdated package and modernized it with a stock EuroCase (EU311) fitted with a custom vacuum-formed insert to secure and display the pen. Complementing a stock case with a custom interior is the perfect solution for budget-conscious projects that require a highly customized appearance; the minimal tooling helps to keep costs in check. The case exteriors were hot stamped with silver foil and each case is packed in an outer sleeve for additional protection. The customer places a blanket order every six months and accepts releases on a monthly basis. As a safeguard, Source maintains stock for immediate release— the customer is never affected by an unanticipated need for a larger order. This new case reduced the company’s assembly time and, more importantly, increased their total sales. The project’s success has led to additional orders for displays and other case solutions. View Other Related Case Studies

Case Study:Wooden Surgical Instrument Display Case

The Challenge

A medical device manufacturer needed cases to display their surgical products in accordance with user feedback. They wanted a stylish case that would allow the sales force to make a dynamic presentation.

The Response

Our sales and engineering team worked with the customer to develop 30 different kits featuring all the tools used in medical procedures…a few hundred components in all. For the initial kits, Source received all the parts that needed to be incorporated into the presentation. More recently, we were provided with CAD drawings of the parts which provided enough technical information to allow us to propose the optimal layout even though the physical pieces were not available.

The Solution

Source designed a series of wood cases fabricated from maple with a cherry stain and lacquered finish. The top edge of the case was routed to fit a lift-off lid in the recess. Both the lid and front panel were laser engraved with the company identification and logo. The interior was fitted with a die-cut flocked foam insert; each cavity was layered to the appropriate height so the components would lie at the same level. Photo-etched aluminum labels were inserted into foam cavities to identify each product. As products are updated and new ones are introduced, they can be quickly incorporated into the new system. View Other Related Case Studies

Case Study:Medical Instrument Trade Show Display

The Challenge

Representatives from a leading medical device company wanted to combine a sales demo case with a trade show display case to make a convenient and portable carrying case for comprehensive presentations. The case had to be large enough to hold literature and a variety of medical tools and it also had to account for the delicate nature of its contents and the client’s need to effectively showcase them.

The Response

Our stock cases proved too big and unwieldy for this project so we chose an Alumiwrap case for a compact, custom footprint and a sleek, minimalist aesthetic.

The Solution and Results

The case exterior was silkscreened with two PMS color-matched logos for branding and the interior was lined with foam to fit two solid maple trays. Each tray held a custom foam insert routed to the precise measurements of the instrumentation and was laser engraved with the company’s logo and product description. Handles were cut into the bottom tray for easy removal and access to the client’s literature hidden beneath. The top tray was designed with a tapered angle to better showcase the client’s display in the open case. To secure the client’s smaller instruments, a piece of Plexiglas was friction fit into the foam for protection and an added visual effect—a finger notch was cut for removal of the plastic. View Other Related Case Studies