Carrying Cases

Chapter One – What is a Carrying Case?

A carrying case is a way of conveniently organizing and transporting a collection of similar or dissimilar items for future use. There is a type and kind of carrying case to fit every possible application from protecting and storing cell phones to cases for speaking systems and technical equipment. They are an essential part of safely transporting sensitive materials and keeping them from harm.

The design, shape, size, and dimensions of carrying cases varies according to the items that are to be carried. Depending on the use of the carrying case, it can be made from reinforced fabric, plastic, aluminum, nylon, leather, wood, or a combination of materials.

Specially designed carrying cases, like the one picture below, are made to fit a specific application and individually manufactured.

An additional feature of carrying cases are foam insertions that are patterned to tightly hold devices, tools, components, and complex instruments in place.

Chapter Two – How are Carrying Cases Made?

The manufacturing of a carrying case is determined by how it will be used. Off the shelf cases, found at department stores and online, are quite different from cases made for special applications designed to carry scientific instruments and delicate equipment.

Carrying cases are made from a variety of materials that include aluminum, plastic, wood, strong, sturdy fabric, lightweight metals, and leather. The basic requirement for carrying cases is that they be durable, flexible, and easily carried. Certain varieties of carrying cases use a combination of materials to enhance endurance.

Making Carrying Cases

The construction of a carrying case depends on its final purpose. Cases used for air travel have to meet special qualifications and requirements regarding the type of material used in construction, thickness, reparability, and latches. Most manufacturers produce cases that far exceed the basic case requirements.

Carrying Case Materials

Carrying cases are made from lightweight metals as well as heavy duty fabrics such as nylon and neoprene rubber. Plastic cases are blown or rotary molded and may have a cloth or foam padding liner.

Plastic Cases

Blow Molded Plastic Cases

In the blow molding process for plastic cases, plastic is blown into a metal mold. The plastic is forced to evenly cover the surface of the mold as air fills the center of the molten plastic. The final case is uniformly shaped without seams or gaps. Plastic case manufacturers use thermoplastic for its durability, pliability, flexibility, and longevity.

Thermoforming Process

The thermoforming process involves taking plastic sheets and using heat, vacuum, or pressure to form the sheets into solid three dimensional objects. Rolls of plastic are loaded on a spool from which the plastic is fed into the molding machine. The plastic sheets are heated to make them pliable and formable without being melted. Molds are compressed against the sheets of plastic to form the shapes of carrying cases. Once removed from the mold, the shaped case is trimmed, inspected, and moved on for further processing.

There are three forms of thermoforming, mechanical, vacuum, and pressure. With vacuum thermoforming, negative pressure is used to draw the preheated sheet into the mold cavity. Unlike vacuum thermoforming, pressure thermoforming uses positive pressure to force the plastic into the mold. As the name mechanical indicates, positive and negative molds are brought together over the preheated plastic sheet.

Injection Molding

Molds for injection molding are made of steel and carefully crafted for repeated use. The material for injection molding is fed into a barrel where it melts as it is moved along the barrel by a helical screw. At the end of the barrel, the melted plastic is fed into the mold, a representation of which is pictured below. In two shot molding, separate materials can be combined to add color and different characteristics to the final case. Injection molding is limited in the sizes of the cases it can produce.

Rotational Molding

Rotational molding is used to produce very large cases with exceptionally accurate tolerances. As with all of the other plastic processes, rotational molding begins with a mold that is usually a few feet in width, length, and height. Raw plastic resin is loaded into a closed mold that has the shape of the top and bottom of the case to be formed.

The mold is enclosed in a frame that is capable of rotating on multiple axes. The assembly of mold and frame are moved into a heating chamber where they are heated sufficiently to melt the plastic resin. As the heat is applied, the frame rotates spreading the melting resin to all mold sections forming an even coating.

The rotational molding process is capable of forming any type of case, such as ones with double entry and lift off and hinged lids. Most cases produced by rotational molding are made to order or special orders. The complete process is represented in the image below.

Aluminum Cases

The process for the manufacture of aluminum cases is similar to the thermoforming process and begins with a flat sheet of aluminum that is put through a rolling or extrusion process to form the exterior of the case. The textured aluminum sheets are bent, shaped, and formed to conform to the case’s top and bottom design. A frame is placed over the top edges of the bottom and top to give the case even proportions completely around the case and ensure a tight seal when the case is closed.

Handles, hinges, and corners of the case are riveted or welded to form tight connections. With many medium or large cases, wheels are added for convenience and ease of handling. The central design of aluminum carrying cases is to ensure the case is able to withstand the harsh and stressful conditions they will face.

Neoprene Cases

Neoprene, or polychloroprene rubber, is a non-conductive waterproof material that is exceptionally sturdy. The thickness of neoprene and its soft pliable exterior make it an excellent protector from punctures, weather conditions, or other abuses.

Nylon Cases

Nylon carrying cases are created to carry audio and visual equipment and have a padded interior to protect speakers, mixers, and other equipment. They come in a wide variety of shapes, colors, sizes, and have exceptional durability. Nylon carrying cases have interior padding, are resistant to tears, and maintain their shape in all types of conditions after years of use.

Leather Cases

Leather carrying cases vary according to the grade of leather used to produce them. Full grain leather has not been changed or manipulated. It is the hide of an animal after the hair is removed. It has a unique texture and durability. Full grain carrying cases have excellent durability but are expensive. Lower grade leathers are less expensive but not as durable.

Wood Cases

Wooden carrying cases are made from pine, cherry, birch, or mahogany and are sturdy and reusable. Interiors of wooden carrying cases are made from wood, plastic, foam, or fabric with exteriors covered in leather, plastic veneer or fabric.

Carrying Case Design

Carrying case design depends on the needs of the customer. Manufacturers take the ideas of customers and develop prototypes or proposed solutions until the design is what the customer needs. There are certain aspects of case design that tend to be overlooked since they are minor and seem to be inconsequential, such as handles, types of hinges, locking mechanisms, endurance of materials, or other details that seem unimportant. In the design process, it is important to consider all the components to ensure a successfully durable carrying case.

American Transportation Association (ATA) cases have more stringent requirements in regard to their design. To meet ATA standards, cases must be vibration and shock resistant and can be made of a variety of materials including wood with a plastic veneer, plastic board, aluminum, and certain types of sheet metals. For protection from damage, handles and latches are recessed. The ATA has a list of standards for acceptable cases, which determine a case’s classification and durability.

Chapter Three - Uses for Carrying Cases

The uses for carrying cases are as broad and varied as the number of available cases with new ones being developed every year. As more and more commercial activities are being completed at customer locations, carrying cases are being designed to meet the ever changing needs.

The kinds of Carrying cases vary as new things to be carried are developed and technical advances in the industry are discovered. Innovations, inventions, and prototypes are constantly being implemented, which lead to new uses for carrying cases.

The Uses for Carrying Cases

Instrument Cases

Instrument cases are designed to protect technical equipment, such as a calculator or sensitive chronometer. Small, handheld instrument cases come in various styles that make the instrument easily accessible. For carrying larger instruments or ones with several components, the case is designed to match the size of the instruments or components.

Divider Cases

Divider carrying cases are divided into sections for parts, components, and instruments to snuggly fit. They are designed for the safe transportation of technical or fragile equipment with dividers made of tightly packed rubber or polyethylene foam.

Foam Insert Cases

Foam insert carrying cases are like divider cases. They are divided into sections using soft foam material that is cut to the exact shape of the items to be carried. All foam insert cases are custom designed for their applications. The foam is cut to the exact specifications and measurements of the pieces to be carried. This is especially helpful when the case has to endure rough handling of delicate and sensitive equipment.

Pouch Cases

Pouch carrying cases are another method of carrying instruments. They are unlike divider and foam insert cases since they are usually smaller handheld cases that can be carried on a belt or briefcase. Pouches can be attached to the side of a case, as seen in the image below, as additional space on a large carrying case. They serve as an extra means for carrying smaller items.

Catalog Cases

Catalog carrying cases have a hard firm outer shell made of a vinyl coated fabric or plastic. Vinyl coated catalog carrying cases have the appearance of leather and are designed for heavy use. The outer shell must be washable, resistant to cracking, peeling, and stains. There are hinges on the flaps to allow for easy access.

Computer Cases

Computer carrying cases must be designed to meet specific standards. They have to be watertight, able to protect the device if dropped, and corrosion and dust proof. Computer carrying cases can have a solid hard exterior made of plastic, aluminum, vinyl, or leather. Specially designed computer carrying cases have a foam insert, as seen in the image below, to snuggly hold the computer.

Portfolio Cases

Portfolio carrying cases are designed to carry materials for presentations and exhibition. They are made from a variety of materials that include aluminum, leather, or various types of soft sturdy fabrics. There is some confusion regarding portfolio cases since there are so many varying definitions. For manufacturers, a portfolio case is made to carry graphics, artwork, or items for display. They are made of materials that protect the contents and keep it from being damaged.

Presentation Cases

Presentation carrying cases have a hard exterior and are tightly sealed with latches. A collapsible handle and wheels may be added to make it easier to move. The interior has a lining or cushion to protect materials from being scratched or damaged. Foam can be custom fitted to the items being transported to prevent shifting or movement.

Sample Cases

Sample cases are a marketing tool for carrying samples of products, presentation materials, product literature, and documents. Depending on the products to be presented and the weight of the materials, they can be designed with rollers and a telescoping handle. Sample carrying cases are an important asset for salespeople since they offer the ability to bring office materials to a client meeting.

Shipping Cases

Shipping carrying cases are specially designed cases that are made to protect the contents from shock, vibrations, moisture, dust, and damage. They are made of sturdy materials such as aluminum, wood, steel, fiberglass reinforced polyester, or high density plastic. Due to the varieties of their applications, they come in a wide assortment of sizes.

Tool Cases

Tool carrying cases can be standard or custom designed in any size or configuration. They can protect the contents from moisture, salt spray, dust, and immersion. Tool carrying cases are made from a wide variety of materials that include aluminum, high density polyethylene, reinforced polyester, carbon fiber, and low density polyethylene. There are a wide assortment of features that can be added to a tool carrying case, including wheels, zipper enclosures, compartments, and shelves.

Trade Show Cases

Trade show carrying cases are designed to move large display materials. They are organized for easy access for assembly and disassembly of show presentations. Trade show cases are made from durable materials and have a set of wheels for easy maneuverability. Handles are in various locations on the case to assist in controlling the case‘s movements. Heavy duty sturdy latches are included to ensure the case is tightly sealed.

Personal Utility Case

A personal utility case is designed as a protective measure for items that cannot afford to be damaged. They have an exterior layer of material that is able to withstand bumps, shocks, and vibrations. The interior of the case is air tight such that dust or particulate matter are prevented from contaminating items stored in the case. Personal utility cases are an ideal and inexpensive way to protect sensitive credit cards, phones, and personal items.

Chapter Four - Types of Carrying Cases

The types of carrying cases vary as much as their uses with some designs being the foundational traditional carrying case that everyone appreciates and depends on. The distinction between the types of carrying cases is dependent on the materials used to manufacture the case, carrying case standards and regulations, and the purpose for which the case was designed.

Heavy Duty Cases

Heavy duty carrying cases are made from the same materials that are used to produce shipping containers but are lightweight and easy to use and carry. They are designed to exceed American Transport Association (ATA) standards and requirements. Heavy duty carrying cases are reinforced with ribs for extra protection and durability and made of aluminum, high grade plastics, stainless steel, and certain gauges of steel.

Soft Sided Cases

Soft sided cases are made from fabrics, canvas, or vinyls in unlimited colors, sizes, and designs. They are water and dust resistant capable of withstanding the harshest conditions and inclement weather. The soft pliable interior provides extra protection for instruments and materials. A major benefit of soft sided carrying cases is their lightweight and flexibility.

Gun Cases

Gun carrying cases vary according to the type and size of weapon. They can be soft or hard sided but normally have a soft layer on the interior. There are a strict set of regulations regarding gun carrying cases that informed gun owners are aware of. People who enjoy guns, handguns, shotguns, and rifles take extra steps when traveling with their weapons to ensure safety, which is one of the benefits of gun carrying cases.

American Transport Association (ATA) Cases

ATA carrying cases, also known as road or flight cases, are built to protect motion picture equipment, production equipment, musical instruments, and any other sensitive equipment that have constant movement. The ATA has developed a set of guidelines for cases that must travel more than 100 times. The standards for ATA approved carrying cases are outlined in ATA’s Standard 300, Category 1.

Hard Sided Cases

Hard sided carrying cases are made from titanium, wood, thick plastic, and aluminum. They have multiple uses including shipping, travel, and storage of sensitive instruments. Hard sided carrying cases serve the dual function of a traveling case and storage case because of their sturdy construction.

Rolling Cases

Rolling carrying cases have small wheels attached to the bottom for convenience and to avoid the need to carry the case. They are ideal for large, cumbersome instruments and devices. Rolling carrying cases have telescoping handles for easy maneuverability and come in a variety of sizes with several interior padding options.

Storm Cases

Storm carrying cases are designed for severe conditions and have an exceptionally sturdy and hard exterior made of extremely durable material to protect fragile or sensitive instruments and equipment from harm. When not in use, they are excellent to use as storage containers since they are able to protect materials from contaminants and harsh conditions. The interior of storm carrying cases is coated with a form of soft fabric or foam.

Protector Case

Protector cases are made of exceptionally sturdy material designed to combat hostile environments and hazardous conditions. Technical instruments are necessities, regardless of the location, and are typically delicate and complex devices used to record data, connect with teammates, and save a memory. Protector cases provide increased protection and safe storage for these special implements when they are not needed.

Protector cases are watertight, crushproof, dustproof, resistant to vibrations and impact, and have solid thick walls made of lightweight material. They are designed with double latches to avoid being accidentally opened by impact and are an ideal solution for preventing damage to hand held electronics.

Air Case

Air cases are classified as protective cases. Like other protective cases, air cases are made of exceptionally sturdy but lightweight material and are designed to withstand impacts and shocks. They have an airtight design that prevents air and dust from entering the case. Air cases are made in a wide variety of configurations to meet the needs of any application.

The selection of air cases includes ones for traveling, hiking, or simply keeping electronics safe. Each type of air case has the same features regardless of their size and can come with dividers for extra protection and safety.

Chapter Five – Specialty Carrying Cases

The manufacture of specially designed carrying cases is constantly growing as new uses for carrying cases grows with the introduction of unique and unusual equipment. Cases that are specially crafted and designed are produced to serve a single function and are created from highly sophisticated engineering and planning.

Specialty Carrying Cases

Military and Defense

The demanding conditions of military operations require equipment and materials capable of withstanding the stress of harsh environments. Aside from being durable, military carrying cases have to be watertight, shock, corrosion, and dust proof, and are designed for easy handling, such as loading and stacking.

Medical

Medical equipment is fragile and expensive. It must be stored in durable cases to prevent damage since it is a necessary part of saving lives. The main stipulation for medical carrying cases is superior protection and dependability in a crisis. There are a wide variety of medical carrying cases, which can contain equipment, medications, and materials to treat wounds.

Fire and Rescue

As with medical carrying cases, fire and rescue operations require equipment that does not fail in a crisis. Fire and rescue carrying cases must be portable and lightweight but durable enough to withstand hazardous conditions. They come in several designs and with organizational inserts for immediate access to critical life saving equipment.

Veterinary

As with human care, veterinary carrying cases have specific requirements. They must be capable of hygienically transporting diagnostic supplies, medications, and consumables. Cases have to have document pouches and be made of highly durable materials such as aluminum or synthetic leather. Since veterinarians work in a wide variety of environments, the cases have to have large storage space for collection of samples.

Hazmat

Shipping and moving hazardous materials require cases that strictly adhere to government regulations regarding the handling of such materials. Hazmat carrying cases are custom designed to fit the specific applications in compliance with legal stipulations.

Drone Hangar

Drones serve several purposes aside from personal use. They can be used to explore terrain, view an oil field, or survey a battlefield. Regardless of their use, they are expensive and have to be treated with the greatest care.

Chapter Six – Materials Used to Make Carrying Cases

The materials used to make a carrying case must be durable and able to withstand abuse. Plastic is the most common choice since it is resistant to so many harsh conditions. Other materials include aluminum for its corrosion resistance, leather for its durability, sturdy fabrics for their flexibility, rubber for its ability to maintain its shape, and wood for its protection and reliability.

Carrying Case Materials

Plastic

Plastic is the most common material for the manufacture of carrying cases. It is airtight, water resistant, crush and dust proof, and exceeds ATA specifications. Plastic carrying cases can be blow molded to any shape and have smooth seamless surfaces.

Aluminum

Aluminum cases are lightweight, durable, and corrosion and dust proof. Strength and endurance of aluminum has made it a perfect solution for carrying cases. Aluminum cases vary in size from small briefcases to large shipping cases.

Wood

There are certain woods that are ideal for producing carrying cases. In most cases, wood serves as the frame and box, which is covered with another material such as vinyl, plastic, or a heavy fabric.

Nylon

Nylon is very versatile, durable, expandable, and self-healing. It comes in several colors and thread sizes, which makes it useful for the interior and exterior of the case. Nylon carrying cases are ideal for conditions of heavy use. Since nylon is tear resistant, it has a long life span of use with colors that do not fade.

Leather

Leather is durable and comes in various grains. Natural leather tanned directly from an animal is the strongest. There are over 24 animal skins that can be used in the production of leather cases.

Neoprene

Neoprene is a highly durable and resilient synthetic rubber that is produced as a solid or in a soft flexible latex form. It maintains its strength and endurance in harsh conditions, which makes it ideal for the manufacturing of carrying cases. One of the major qualities of neoprene is its resistance to oils.

Conclusion

• A carrying case is a way of conveniently organizing and transporting a collection of similar or dissimilar items for future use.
• The kinds of carrying cases increase as new things to be carried are developed and technical advances take place in the carrying case industry.
• The materials used to make a carrying case must be durable and able to withstand abuse.
• The design, shape, size, and dimensions of carrying cases varies according to the items that are to be carried.
• An additional feature of carrying cases is foam insertions that are patterned to tightly hold devices, tools, components, and complex instruments in place.