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Introduction
This article takes an in depth look at hard cases and their uses.
You will learn more about topics such as:
What is a Hard Case?
How Hard Cases are Used
Materials Used to Make Hard Cases
How Hard Cases are Made
Accessories for Hard Cases
And Much More ...
Chapter One – What is a Hard Case?
A hard case is a type of carrying case that is made from molded plastic, aluminum, veneered or laminated wood, or different types of metals. They are the most secure and durable forms of carrying cases and come with features that offer extra protection. The category of hard cases encompasses a wide array of cases that come in various sizes to fit the needs of the materials to be carried. They can have wheels for easy handling and be a few feet wide and high.
The original carrying cases were hard cases due to the hazards, stress, and harmful conditions they were required to endure. Over the years, as new materials were synthesized, soft sided cases became popular for their convenience. Regardless of the many innovations and improvements in carrying case design, hard cases remain a necessity.
Chapter Two – Uses for Hard Cases
The standard hard case that is used to carry tools, instruments, and monitors has the shape of a large briefcase. It is a type of hard case that comes with a variety of features that make it easy to access items and has organizational features. In most instances, when people imagine a hard case, they envision a hard sided briefcase. Hard cases go far beyond tool cases and briefcases and have been specially designed to meet the standards for industrial and transportation use.
Hard cases can carry a complete sound system, large instruments to measure wind velocities, and ammunition and guns. As society has grown and progressed, the need for unique and unusual hard cases has rapidly advanced, with new innovations and designs being regularly introduced.
Hard Case Uses
Instrument Cases
Instrument cases are used to protect sensitive and delicate instruments that can be damaged by mishandling. They are made of high quality materials such as high density plastics, aluminum, wood, and sheet metals. Instrument cases are specially designed with inserts made of foam rubber or plastic that have the exact dimensions of the devices to be protected.
The design behind instrument cases is based on the concept that the slightest type of impact can significantly diminish the performance of a sensitive instrument. It is for this reason that instrument cases are the sturdiest form of the hard case made of indestructible and impregnable materials.
There are several sizes of instrument hard cases each of which has a rectangular design with locking latches, high performance hinges, and extra strength unbreakable handles.
Shock Mount Cases
Shock mount cases are hard cases that have specially designed inserts that absorb any shock the case may encounter during transport. They have an added layer of foam that is placed between the inner and outer box that can handle the harshest and most intense treatment.
Each of the design factors related to the development of shock mount cases is determined by the customer and the types of materials that they need to be protected. In addition to their shock resistance, as an extra layer of protection, shock mount cases are tightly sealed to protect against potential water damage.
American Transportation Association (ATA) Cases
The ATA has developed strict guidelines and standards for containers for shipping to protect items being shipped and the safety of materials during transit. ATA cases have the same type of structure as typical hard cases but are required to meet ATA rules regarding materials and construction.
Accepted ATA materials include plastic laminates, fiberglass, and aluminum. Inner walls must be made of multi-layered plywood with aluminum abutments that are bonded with steel rivets. All edges must be covered and protected with knuckle ball corners attached to all eight corners. Long piano type hinges are required for hinged lids.
Latches for ATA cases are embedded and can be twist spring loaded or valence spanning spring loaded. Handles are also embedded to avoid being caught or snagged. Interior foam choices include ester, polyurethane, or expanded polyethylene plastic.
The rules for ATA cases are outlined in ATA Standard 300, Category 1. All manufacturers who wish to have their hard cases qualified as ATA acceptable submit their cases for testing to prove that each aspect of the case adheres to ATA specifications.
Waterproof Cases
For a hard case to be classified as waterproof, it must be airtight, watertight, and dust and rust proof. Waterproof hard cases can withstand the effects of extreme weather and are made of high quality resins capable of withstanding temperatures ranging from -40°F to over 170°F. Hinges and latches are made of high quality stainless steel or plastic that is rust and corrosion resistant.
Computer Cases
Hard sided computer cases are necessary for the protection and safety of valuable equipment and data. Laptops are a major investment and an essential part of business planning and record keeping. Salesmen depend on them to close deals while repairmen track their calls and record what they did at a customer’s site. Students depend on computers to take notes in class and to do work during breaks. In all cases, computers are constantly being moved in and out of vehicles and placed on desks and tables.
In order to protect computers during their continual movement, users depend on hard cases that serve as protection for the computer and offer a place to organize documents and keep a mouse and charging cables as well as other computer accessories. The many varieties of computer hard cases range from ones with filing pockets to ones with padding like shock mount cases.
Any form of impact or shock can damage a computer such that it loses data and is unable to operate. Hard cases prevent such scenarios and offer peace of mind to users.
Shipping Cases
The main purpose of shipping cases is to provide protection and security to ensure that the contents of the case arrives safely and intact. Shipping cases are made from a variety of materials, which makes it possible to choose the right case to fit the needs of the materials being shipped. As with other hard cases, shipping cases can come with foam inserts for extra protection.
A basic characteristic of shipping cases is their ability to absorb shock and withstand impact without cracking or rupturing. Any form of shipping container experiences frequent shifting and jarring against other cases and materials while in transit. Shipping cases are able to endure being banged, crushed, and struck as part of the transportation process.
Shipping cases come with all of the features of traditional cases with many of them having castors for easy mobility. They can be custom designed to ship trade show displays and setups. Specially designed shipping cases are manufactured to ship computer components with protection against EMI and RFI interference.
Gun Cases
Gun cases are necessary to protect firearms and keep them safe from being dropped and scuffed. Guns are most vulnerable to damage during transport especially when moving over rough terrain out in the field. All gun cases are designed to protect a gun from harm, regardless of their construction. Hard cases are designed to provide an extra level of protection, including hard drops, being thrown, or rattling around in the bed of a truck.
Hard case manufacturers have developed gun hard cases for every conceivable type of weapon, from shotguns and rifles to ones for large and small handguns. Each type of case has shock resistant foam padding and cutout slots where a weapon can easily be inserted. Additionally, gun hard cases have pockets for ammunition and cleaning supplies.
The many varieties of gun hard cases include ones for a single gun and ones for up to five or more guns. The cases are designed to position a gun safely to protect its firing mechanism.
Portfolio Cases
As with all hard cases, portfolio cases are designed to provide an easy method for carrying and protecting works of art. Additionally, hard sided portfolio cases offer a means for displaying work during presentations or displays. Due to the large sizes of artwork, portfolio cases are available in sizes that range from 1.5 feet up to over 3 feet and have a high density heavy duty plastic shell with depths beginning at one inch.
Portfolio hard cases have several different options for handles that include straps, oversized handles, and custom designed methods for opening.
Tool Cases
Tool cases are the most popular of the different types of hard cases. Their use has steadily grown over the years due to how light they are and their large capacity. Although there isn’t a standard size for tool cases, polyethylene blown ones tend to be the most widely used because of the durability, strength, resilience, and longevity of the polyethylene material.
There is a tool case for any type of repair job with designs that have pallets for organizing parts, tools, and instruments. Tool cases are versatile enough to meet the needs and requirements of any industry. They can be adapted, configured, and crafted to hold any set of tools regardless of how technical or sensitive.
Storm Case
Storm cases are in the same category as shock mount cases, instrument cases, and ATA cases. They are specifically crafted and designed to protect professional tools, gear, instruments, and equipment from damage by inclimate weather or other hazardous conditions.
Included in the design of storm cases are padlock enabled latches, pressure relief systems, specially designed handles, and exceptionally durable case design capable of withstanding the most intense conditions. They are watertight and waterproof as well as crush and dust proof. When a storm hard case is closed and secured, it is theoretically impossible to reopen.
To accommodate the many uses of storm cases, they come in a wide variety of shapes, sizes, configurations, and designs. Foam inserts are typically part of storm cases as shock protection and to keep components dry.
Catalog Cases
Catalog cases serve a function that is similar to a business briefcase but includes features that specifically fit their requirements. They are designed to file and organize sales materials for trade shows, conventions, and presentations. Due to the weight of the materials they carry, they have extendable handles and sturdy wheels included with the standard handles.
Depending on the application, catalog cases can have locking mechanisms and places for padlocks. Unlike typical briefcases, catalog cases can have multiple compartments, dividers, file pouches, and pockets to hold manuals and pamphlets as well as pens, computers, cell phones, and instruments.
There are many uses for catalog cases, including holding files for lawyers, organizing presentation materials for sales representatives, or serving as a compact office for executives. The tight and smooth organization of a catalog case makes everything that is needed for a meeting instantly available.
Sample Case
Sample cases are essential tools for promoting a business, products, services, or part of a marketing presentation. There is a form and type of sample case that can fit the needs of any marketable item. They are what a sales representative depends on when meeting with customers to provide data on a product or service.
In the area of sample cases, hard cases serve more than storage and protection functions. They become a part of the image and impression of a company. When a representative is preparing to meet with a customer, the quality of the tools they use have to create a positive image of the company they represent. A shabby, dilapidated hard case can negatively impact a first meeting.
Case Uses Summary
The twelve examples of hard cases listed above are only a small portion of the many cases that are available from hard case manufacturers. Aside from these few, producers can design, create, and engineer personal cases that can exactly meet the needs of a specific piece of equipment, tool, or application.
Leading Manufacturers and Suppliers
Chapter Three – How Hard Cases Are Made
The manufacture of hard cases takes different forms depending on the type of material being used and the manufacturing process. In the case of metals, hard cases are shaped by presses that force the raw sheet metal into the shape of the case. Several different methods are used to shape high density plastics, with molds being the common factor for most methods.
The shaping and production of hard cases are precision designed processes that ensure that the final product is uniform, sealed, and useful. The importance of the integrity of hard cases necessitates the greatest amount of care in their production.
Making Hard Cases
Plastic Hard Cases
The methods for producing plastic hard cases involve the use of a mold in the shape of the case. Depending on the process, plastic is placed in the mold in different forms from being heated to make it ductile or as solid resin pellets.
Rotational Plastic Molding
Rotational plastic molding is used to produce large plastic cases that have exceptionally accurate tolerances. There are three stages to the process all of which include the rotation of a mold. The apparatus for rotational molding involves a frame that is capable of rotating on multiple axes. Encased in the frame is the mold for the case.
The process of rotational molding begins by placing resin pellets in the two halves of the mold and sealing the mold tightly. Once loaded, the frame begins to rotate and moves into the heating chamber where the plastic resin melts and is evenly spread to the sides of the mold by the rotation of the frame.
The rotational process continues until the resin has melted and been completely distributed, which takes an extended amount of time. When the molten plastic has been completely spread across the surface of the mold, the rotating frame moves into the cooling chamber where the mold is cooled by water and air or both. Once cooled, the completed shell of the hard case is removed and prepared for finishing and the addition of latches, hinges, and other components.
The complete process of rotational molding or rotomolding is depicted in the image below.
Injection Molding
Injection molding begins with the same plastic resin that is used for rotational molding. In the case of injection molding, the resin is poured into a hopper that is connected to a barrel that contains a helical screw. After the solid resin pellets enter the barrel, they are slowly moved along the barrel by the screw. As the pellets travel the length of the barrel, they are heated to their melting point.
At the end of the barrel is a nozzle connected to the mold cavity in the shape of the hard case. Under pressure, the molten plastic is forced into the mold cavity until it evenly covers the surface of the mold. When the predetermined amount of plastic is inserted into the mold, the completed product is cooled by water or oil.
The demolding, removal of the molded part is a critical part of the process and must be completed carefully to prevent deforming. Common methods for demolding are ejection or stripping, which are selected in accordance with the type of product to be removed.
Thermoforming Plastics
Thermoforming of plastics is unlike rotoforming, blow molding, or injection molding, which use melted resin pellets as their raw material. The material for thermoforming is sheets of plastic, usually in rolls, that are heated and fed into a die where they are compressed into the shape of a hard case.
The thermoforming process begins with huge rolls of plastic that are attached to the forming machine. The molds for thermoforming are made of high quality steel that has been carefully crafted to the shape of the hard case. As sheets from the roll are fed into the die, they are heated to a point where they are ductile and pliable.
Once the sheets are in the die, its two halves are compressed together to form the shell for the hard case. The molded shape is cooled, trimmed, inspected, and sent on for further processing.
Mechanical, vacuum, and pressure are the three types of thermoforming. Although the initial process for each type is the same, the heating of the plastic sheets, how the sheets are formed varies between the types. With vacuum thermoforming, negative pressure is used to draw the preheated sheet into the mold cavity. Pressure thermoforming uses positive pressure to force the plastic into the mold, while the mechanical method uses positive and negative molds that are brought together to form the hard shell.
Blow Molding
Blow molding uses heated plastic fabric that is blown by forced air into a mold cavity. It is a method used to form all types of hollow plastic shapes. Somewhat like rotational molding, blow molding evenly distributes the plastic material across the surface of the mold with uniform thickness.
The blow molding process begins by heating plastic material to form a parison, which is secured to the mold. Air, under pressure, is blown into the parison to evenly expand it across the interior of the mold to form the hard case.
Blow molded cases can be single or double walled. The choice of which type of wall depends on how the case will be used with double walled cases having extra strength and exceptional quality. As with single walled cases, double walled cases can have customized foam inserts to specifically meet the needs of what the case will carry. Additionally, the interior of the case can be shaped and molded without the use of foam inserts. The blow molding process makes it possible to customize, design, and configure a hard case to meet any type of conditions.
Other Hard Case Manufacturing
Although plastic is a common material used to manufacture hard cases, it is not the only material used to produce them. Various metals and wood are also used to make them, with wood normally having a veneer or laminate applied to enhance its strength, durability, and appearance.
Metal Hard Cases
The manufacture of metal hard cases begins with sheets of metal that are delivered in heavy rolls. Of the different metals, aluminum is the most common material due to its strength and lightweight. Stainless steel, carbon steel, and more expensive metals are also used.
The initial process for making metal cases is to cut the rolls of metal into sheets, which are compressed, bent, and folded to form the shell for half of the case. An essential part of the process is to connect a frame to the shell. Its purpose is to connect the four sides of the shell to keep them secure and even. The frame is riveted to the shell using steel or aluminum rivets.
To further seal a metal hard case, the corners are coined, knuckled, and secured using more rivets. For some sizes of hard cases, wheels are added at the corners for easy handling. Once the two halves of the shell are shaped, interior accessories are added, which can include various types of linings such as rubber, foam, plastic, or cloth.
Other forms of metal hard cases use sheets of metal that are connected sheets and strips with each edge riveted with knuckles at the corners or are welded along the edges. This form of metal case is lined with various types of materials, with rubber and foam being the most common. Sheet metal formed cases are made in a full range of sizes from ones the size of briefcases up to one's large enough to be shipping containers. The processing of this form of metal case is very similar to the manufacture of wooden cases, which have wooden sides and pieces that are assembled into a hard case.
Wooden Hard Cases
Unlike plastic or metal hard cases, wooden cases are assembled from pieces of wood and strips of metal using crown topped or domed topped metal screws that are corrosion and rust resistant. The need for assembly is one of the reasons that wooden cases are not as widely used as plastic cases, which are formed by a single piece of solid plastic.
Although wooden hard cases are referred to as wooden cases, in reality, they are not made just out of wood. Hard sided wooden cases use wood with a veneer or laminate for extra protection and durability. For heavy duty wooden shipping cases, the edges are connected with strips of aluminum, steel, or some other metal. The eight corners of wooden cases are covered with knuckles regardless of how the edges are connected.
Larger wooden carrying cases have wheels that make it easier to move the case. The cut and shaped sides of a wooden case are connected to its metal frame using domed topped screws. The corners of the lid and frame are connected to the sides with multiple screws to ensure a tight and secure connection.
Case Manufacturing Summary
The plastic, metal, and wood cases described above are a sampling of the different ways used to manufacture hard cases. Each hard case manufacturer has their own proprietary methods for producing high quality hard cases and are constantly refining and searching for methods to improve and enhance their production methods.
Chapter Four – Materials Used to Manufacture Hard Cases
The majority of hard cases are made from thermoplastics that can be shaped and configured to fit the needs of any dimensions and requirements. Aside from molded plastics, various types of metals are also used to produce hard cases, with aluminum being the most popular due to its many positive characteristics and properties.
Materials chosen to manufacture hard cases are required to have specific properties and qualities, including durability, longevity, strength, and resilience. Hard-sided carrying cases are expected to be able to endure stressful and demanding conditions without being damaged or failing. More stringent demands are placed on hard cases compared to soft or semi soft cases.
Hard Case Materials
Polyethylene (PE) Material
Polyethylene is a thermoplastic with a variable crystalline structure and is the highest produced plastic in the world. There are four types of polyethylene which are low density (LDPE), linear low density (LLDPE), high density (HDPE), and ultrahigh molecular weight (UHMW). HDPE is the type of polyethylene plastic used to form and shape hard cases.
HDPE has a very high crystalline structure, which makes it suitable for the manufacture of hard cases. It is strong, durable, lightweight, and chemical resistant and can easily be fabricated into multiple shapes using any of the different plastic manufacturing processes.
Aluminum in Cases
The many properties of aluminum make it an ideal material for the manufacture of hard cases. It is lightweight, rust resistant, durable, and easy to shape and configure. Aluminum is capable of withstanding the effects of oils, salts, chemicals, and extreme variations in temperature.
Hard cases made of aluminum are actually made of various types of aluminum alloys since pure aluminum is too ductile and pliable. A major contributor to its use as a hard case is its non-conductivity, which makes it ideal for shipping electrical components.
Wood Material
Wood is the oldest of the carrying case materials and has been used for centuries to produce a wide variety of cases, containers, and boxes. In the modern era, wood carrying cases have been enhanced with various coatings such as veneers and laminations that protect the wood against scarring, gouges, and other damage.
Of the different types of materials, wood is used to produce hard cases that have an elegant and aesthetic appeal, especially when the wood grain is emphasized.
Fiberglass Reinforced Polyester (FRP)
FRP is a polymer that has been reinforced with fiberglass. The material is anisotropic, which means that the fiberglass particles are in a single direction. It is a high strength material with excellent density, corrosion resistance, and electrical, magnetic, and thermal properties. FRP is sometimes used in place of metals where load capacity is important. Carbon, glass, and aramid are used in its manufacture.
Chapter Five – Hard Case Accessories
The essential and defining part of a hard case is its exterior. It is the main reason hard cases are used for applications requiring exceptional protection, durability, and strength. For a hard case to be the most effective, it is important that they have various addons that enhance their use and offer extra protection. These additional items take the forms of zipper cases, pallets, foam inserts, and rubber padding.
Accessories for Hard Cases
Foam Inserts
Foam inserts are an extra layer of protection that is flexible and shock absorbing. They have the shapes of the items that they are securing and keep them from moving or bumping each other. Foam inserts serve as cushioning material for sensitive and vulnerable materials.
The properties of foam allow it to be shaped and molded to fit the dimensions of any product. Since the foam is exceptionally durable, it will last as long as the case.
Pallets and Hard Cases
Pallets increase the area available in a hard case and offer an additional level of organization. They are made of a variety of materials with sewn on pockets made of durable fabrics that can withstand constant use. Pallets can be attached to the hard case and be pulled out like files or be flat pieces that can be piled on each other.
The uses and designs of pallets vary between manufacturers and designers. In all cases, they are a convenient method for keeping track of tools, devices, instruments, and other pertinent materials.
Wheels for Hard Cases
Wheels for hard cases have become a necessity as the cases get larger and store more and heavier items. Hard cases demand and require wheels of a high quality. They must be capable of bearing the weight of the items in the hard case and are engineered with ball bearings capable of withstanding the load. There are several methods for connecting the wheels, with ones being screwed or riveted to the case being the most common.
Telescoping Handle
Hard cases with wheels necessitate the use of a telescoping handle to maneuver and guide the case. Telescoping handles are built into the case and are easily pulled out and up and locked in place. They are made of materials that match the design and quality of the case, from ones made of heavy duty aluminum to ones made of high density plastics.
Case Handles
Handles are a vital part of a hard case and allow the user to carry, maneuver, transport, and place a hard case with ease. The common types of handles are:
Standard Grip
Standard grip handles are attached to the case with screws or rivets and have a bar design. They are normally hinged and can be positioned flat on the case. Some hard cases have handles that are embedded and fit into an indented portion of the top of the case.
Spring Loaded
Spring loaded handles have a spring mechanism that allows them to be recessed in the lid until they are needed.
Straps
Straps are used on hard cases to make them easier to carry. They are commonly found on portfolio hard cases and hard cases for large tools.
There are three types of materials used to make handles: metal, plastic, and rubber. Metal handles are made of aluminum, steel, and stainless steel, depending on the design of the case. High density plastics are also used for handles and can be connected to the case with metal brackets. To make handles more comfortable, hard case handles may have a foam or rubber covering or be made exclusively of rubber.
Conclusion
A hard case is a type of carrying case that is made from molded plastic, aluminum, veneered or laminated wood, or different types of metals. They are the most secure and durable of the forms of carrying cases and come with features that offer extra protection.
Hard cases go far beyond tool cases and briefcases and have been designed to meet the standards for industrial and transportation use.
The manufacture of hard cases takes different forms depending on the type of material being used and the manufacturing process. In the case of metals, hard cases are shaped by presses that force the raw sheet metal into the shape of the case. Several different methods are used to shape plastic, with molds being the common factor for most methods.
The majority of hard cases are made from thermoplastics that can be shaped and configured to fit the needs of any dimensions and requirements. Aside from molded plastics, various types of metals are also used to produce hard cases, with aluminum being the most popular due to its many positive characteristics and properties.
The essential and defining part of a hard case is its exterior. It is the main reason hard cases are used for applications requiring exceptional protection, durability, and strength. For a hard case to be the most effective, it is important that they have addons that enhance their use and offer extra protection. These additional items take the forms of zipper cases, pallets, foam inserts, and rubber padding.
Leading Manufacturers and Suppliers
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