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Introduction
This article contains information about tool cases and their use.
You will learn:
What is a Tool Case?
Types of Tool Cases
Material Used to Make Tool Cases
How Tool Cases are Made
And much more...
Chapter One: What is a Tool Case?
A tool case is a portable case designed to organize and protect tools and allow easy access and convenient availability. Standard tool cases can be used when working on a project. In addition, specialty and custom-designed tool cases are available for unique and unusual applications. For example, foam inserts that conform to the shape of tools offer extra protection for sensitive instruments and electronic devices.
Many tool cases include ones with a hard outer shell that seals to protect tools from water damage, dirt, damaging liquids, and atmospheric contaminants. Tool cases come in several sizes to accommodate any application, from ones that can be handheld to ones that roll on wheels. Each one is designed to fit the demands and requirements of the user.
A tool case is an essential part of their routine for field technicians, plumbers, truck drivers, and many other professionals. It provides them with efficient and convenient access to the instruments, devices, and equipment they need to complete their work.
Chapter Two: Types of Tool Cases
Unlike the tool box of many years ago, modern tool cases are designed to specifically meet the needs of the user. Manufacturers produce tool cases to fit every profession, application, and condition from ones designed for computer repair to ones capable of carrying tools to repair well heads on oil rigs. The many applications and conditions require the use of durable and sturdy materials that can withstand the demands of the stressful working conditions.
The idea of the old metal box into which tools were packed and thrown has been transformed into hard-walled plastic cases that have compartments to organize tools for immediate access. As with all aspects of society, modern technology has updated and improved the old toolbox.
Blow Molded
Blow-molded tool cases are a rapidly growing form of tool case specially designed to hold electric tools carefully and protectively in place. Several blow-molded tool cases are commonly used to sell a single electric tool or sets of like tools designed for a single application.
The sturdy and durable design of blow-molded tool cases offers excellent protection for tools, especially technical ones. The shaped blow molding securely holds tools in place to prevent them from damaging each other. This form of tool case is ideal for tools with several pieces such as socket sets, screwdriver sets, and testing tools and instruments.
Briefcase
Tool briefcases can be somewhat confusing since they look exactly like a business briefcase. This type of tool case is ideal for technicians when they need to visit a customer site but do not want to disrupt office protocols. In most cases, briefcase tool cases are slightly wider than the average briefcase and made of exceptionally durable material such that they can endure rough treatment.
Much like the average briefcase, tool briefcases come in a variety of styles to fit the user's needs. Tool briefcases have multiple compartments, tool boards, and a partitioned section for documents and manuals.
Foam Insert
Foam insert tool cases are commonly used with breakable tools and must be safely held in place to maintain their calibration. This type of tool case can carry any form of tool but is widely used by technicians who use their instruments to take readings and make technical adjustments. Tool case manufacturers can form fit foam inserts to precisely and accurately fit any tool's shape and configuration.
In some cases, there are tool cases that have foam that is colored to make it easier to see the array of tools. This feature can also be used as a means of organization and cataloging of tools.
Pocket Pallet
Pocket pallet tool cases have become increasingly popular due to the amount of storage space they provide. The case's interior can hold any number of pallets to organize tools and separate them according to their use. Pallets are typically attached to the lid and held in place by a latch to unlock the pallet.
The different types of pallet tool cases make it possible to have ones for extensive tools for repairing and working on large projects. Other types are designed for small tools used for delicate and intricate work.
In the case image below, pallets are in the lid and the body of the case. The ones in the body of the case can be lifted out but keep the tools organized.
Protector
Protector cases are water-tight, crushproof, impact-resistant, and tightly sealed to protect against contaminants, dirt, and dust. They have solid walls made of wood, plastic, or metals that are capable of withstanding extreme conditions and constant use. The nature of protector cases necessitates that they have a solid and lightweight and be easy to handle with durability to withstand any type of environment or conditions. In order for a protector tool case to receive the label of protector tool case, it is subjected to a set of tests that include water submersion, extreme temperature changes, and being dropped from various heights to test endurance.
The designs of protector tool cases take several forms using a wide array of materials that include aluminum, steel, hardwoods, and very dense plastics. These types of cases, aside from their construction, also vary in their size with some cases being very small and uncomplicated to ones that have side pockets, drawers, shelves, and tool racks. In addition to the enhancement of the exterior of a protector case, the interior of protector cases can have padded and shock absorbing materials that prevent delicate and sensitive instruments from being harmed or damaged, a factor that could result in miscalibrations and errors in readings. Of the many forms of tool cases, protector tool cases are of the highest quality and the most sturdy.
Road
Road tool cases are built for travel and are made of rugged, sturdy material that can endure the handling of airline travel. They are made of metal with reinforced corners and tight, secure, durable latches. To be used for air travel, they must meet the standards required by the Air Transport Association.
Travel requires that road tool cases come in various sizes and configurations, from large ones to carry-ons. In addition, many road cases have built-in wheels for added convenience.
Rolling
Rolling ones can be the most durable of the various types of tool cases. They are generally made of high-density polyethylene, enhancing their durability and longevity. In addition, there are several interiors for rolling tool cases with pockets for tools and part placement to ones that have foam shapes for extra protection for tools.
Rolling tool cases are a convenient way for carrying tools and equipment, especially when the items to be taken are heavy or cumbersome. Most rolling tool cases have ribbing to add extra strength and reinforcement.
Soft Side
Soft-sided tool cases have been gaining popularity for many years due to being unbreakable, tear-resistant, and exceptionally durable. They have several combinations of features such as pockets, pallets, loops, and different sizes of compartments. In addition, the material used to manufacture soft-sided tool cases is treated to be moisture repellent and shock-resistant.
The design of soft-sided tool cases includes various exterior features such as side pockets and carrying straps. Though lightweight, soft side tool cases are highly durable and capable of withstanding the same abuse as their hard-sided counterparts. One of the benefits of soft-sided tool cases is how the material gives under strain but has padding to prevent shock to tools.
Super-Sized
Super-sized tool cases are exceptionally sturdy and rugged. Their larger size makes it possible to include added features that enhance the ability to store and protect tools. The enormous size of super-sized tool cases requires a piano hinge to hold the lid. Additional supports are typically added on both sides to support the cover when it is open.
The number of tools and equipment stored in super-sized tool cases requires a locking mechanism, which varies between manufacturers. In addition, super-sized tool cases are made of various materials, from heavy-duty plastics to aluminum and steel.
The few tool cases described here are only a sampling of the available wide selection of tool cases. There is a tool case to fit every industry and profession with specially designed features to meet the needs of specialized applications. Manufacturers also offer customers the opportunity to develop their specialty tool cases for personal use.
Pocket
Of the many varieties of tool cases, pocket tool cases are the more convenient forms of tool cases. They can hold cell phones, precision tools, very small parts, and items that would normally get lost in a larger tool case. Pocket tool cases can be hung on a belt, from a shirt pocket, or strapped to a worker's arm. Tools small enough that fit in a pocket tool case include pliers, lighting instruments, screwdrivers, miniature tools, and sharp-pointed tools.
Pocket tool cases are helpful in organizing tools for precision repairs where equipment to be repaired or worked on are very small and require delicate handling. This type of work is very common for computers, copy machines, cash registers, and electronics. There is a wide variety of tools for these types for equipment due to their many facets and complexity. In many cases, a large tool box would be inappropriate when entering establishments that use such equipment and could interfere with office operations.
As with other forms of tool cases, pocket tool cases come in several designs with different numbers of pockets and different sizes, which can vary from five to ten pockets up to twenty to thirty pockets. Pocket tool cases make tools readily available, a factor that saves time and ensures all necessary tools are on hand.
Leading Manufacturers and Suppliers
Chapter Three: Materials Used to Make Tool Cases
An essential part of tool cases is the types of materials from which they are made. The choice of tool case materials depends on the tools it will carry and the variety of projects or applications where it will be needed. As a result, materials for tool cases vary from ones for DIY tool cases used for projects around the home to ones designed for heavy-duty use on production and manufacturing equipment.
For many years, toolboxes were made from wood and later transitioned into steel and aluminum. With advancements in technology, plastic tool cases became available and have taken over a significant portion of the market. Regardless of the dominance of plastic, modern tool cases are made from many varieties of materials and combinations of materials.
Polypropylene (PP)
Heavy-duty polypropylene makes a wide range of tool cases due to its durability, sturdiness, and resilience. PP has high fatigue resistance, which makes it ideal for manufacturing tool cases. Polypropylene serves as a strong barrier but has an excellent surface finish that lends to a good appearance and enhances its strength and endurance.
Polypropylene has to be handled carefully despite its many exceptional properties, especially in very high and low-temperature conditions.
Nylon
Nylon is a common material for the manufacture of soft-sided tool cases. It has superior strength compared to some plastics and is far better than other fabrics. Nylon is a synthetic flexible plastic fiber that has been drawn into fibers for the manufacture of clothing and household use. It is used to make tool cases due to its strength, elasticity, resilience, and resistance to water.
Soft-sided tool bags have gained great popularity due to their appearance and ability to be configured in various sizes, from ones that can fit in your pocket to ones large enough to carry multiple types of heavy equipment.
The main selling feature of nylon tool bags is the number of pockets they have, which manufacturers emphasize. The versatility of nylon fabric makes it possible to include several pockets for easy organization of tools, especially small precision ones.
Foam Inserts
Foam inserts fit into any style of tool case and are designed to surround precision tools to protect them from shocks, blows, jolts, vibrations, or other forms of harm. The composition of foam inserts includes pieces of foam that are placed in tool cases as a means of protecting the contents of the tool case. They are made of high density types of foam and are widely used for a long list of tools and instruments.
Most foam inserts are made from die cut foam that uses the outline of the tool or instrument to be protected as the pattern for the die. The tight fit of the foam is designed to prevent the protected tool or instrument from shifting or moving. The use of foam inserts in tool cases is to prevent damage to tools when being transported or moved. The majority of foam inserts are a flat black palette of plastic foam that has been hollowed out in a shape that matches the tool or instrument to be protected. The types of foam inserts can widely vary from small and delicate tools to large diagnostic instruments. In many cases, foam inserts have to be custom designed to fit the shape and configuration of a tool.
Although die cut foam method is used to produce foam inserts, other methods include waterjet cutting that is used to form and shape the foam to fit the dimensions of tools. Foam for foam inserts is made from polyurethane, polyethylene, velour, and polyethylene anti-static foam, which are resilient materials and capable of withstanding impacts and vibrations.
Tool Pallets
An essential part of any repair job is having the right tools for the job. An efficient method for ensuring having what you need when you need it is tool pallets that offer more storage space and exceptional organization. Tools can be easily categorized by use and type.
Tool pallets allow technicians to organize their tools according to the tools' job. Pallets have flat, sturdy surfaces with pockets or slots for placing any tool, from delicate precision instruments to standard screwdrivers and pliers. Tool pallets are made of materials with a sturdy core covered with fabric and sewn in pockets or slots.
Plastics and Metals Used for Tool Cases
The many different styles and types of tool cases requires the use of a variety of materials with aluminum and plastics being the most common. Durable and long lasting tool cases require the use of metals. Although aluminum is the most commonly used due to its lightweight, resistance to atmospheric conditions, and strength, specially designed tool cases are made of stronger metals such as certain grades of steel.
Aluminum's lightness, strength, and durability make it an ideal metal for manufacturing tool cases. Combined with other materials to increase its natural properties, aluminum enhances tool cases, improving their appearance and sustainability. There are several varieties of aluminum tool cases that vary in strength, shape, and sizes with the majority having some form of inner lining such as foam, cloth, or molded plastic.
The three series of aluminums that are used to manufacture tool cases are series 1060, series 3003, and series 5052. Series 1060 is part of alloy group 1xxx, which is known for its ability to be shaped and formed into several configurations. The use of series 1060 for tool cases is due to its resistance to chemicals.
Unlike series 1060, series 3003 is a medium strength aluminum that is alloyed with manganese as its main alloy. An aspect of series 3003 that makes it ideal for tool cases is its formability, which makes it suitable for manufacturing any type of tool case. The manganese content of series 3003 increases its strength and differentiates it from series 1060.
Of the three series of aluminums, series 5052 is the strongest. Like series 3003, series 5052 has magnesium as an alloying metal. What makes this series different from 3003 is its chromium content, which further enhances its strength. Regardless of the extra strength of series 5052, it has the same formability as series 1060 and series 3003. The higher strength of series 5052 makes it ideal for tool cases that have to endure stressful and demanding conditions.
Chapter Four: Tool Case Fabrication
Critical to the performance of a tool case is how it is manufactured. There are different methods to determine the performance of a tool case and its many uses. Though strength and resilience are critical factors for tool cases, they are not always part of the requirements or specifications. What is critical is the protection and safekeeping of tools and instruments.
Several methods are used to produce tool cases, which vary by manufacturer, materials, and designs. Every hardware and home improvement store has cases available for DIY users and professionals. In addition, for more complex and specialized applications, there are custom-made tool cases produced to the customer's exact requirements.
Fabricating Tool Cases
Designs
One of the most exciting aspects of tool cases is design. Unfortunately, what may be presumed to be an easy task where an engineer creates a compartment to load tools is a complex and challenging process. There are multiple factors and conditions that engineers have to consider when planning a new tool case.
With the rapid growth of technology, it has become necessary for designers to be creative in their approach to designing tool cases since every situation, application, and circumstance requires a tool case adapted to fit the conditions. The process includes selecting the right materials, fabrics, and other factors.
Materials
The assortment of materials used to make tool cases include nylon, various plastics, aluminum, steel, and vinyl. Of the many choices of materials, fabric cases have become the most popular due to their lightweight, flexibility, and adaptability. However, metal tool cases are usually chosen for more robust repair applications due to the nature of the tools used.
Though not commonly used, leather and rubber are sometimes used to manufacture specialty bags. Included in the characteristics of rubber and leather is their non-conductivity, which makes them ideal for carrying electrical devices and instruments.
Manufacturing Processes
The most common method for making modern tool cases is molding, including blow molding, injection molding, thermoforming, and compression molding. These processes are used to create plastic or polymer tool cases using exceptionally resilient and reliable materials. In addition, the plastic molding process allows manufacturers to include forms, storage bins, and slots in tool cases for organization and convenience.
Tool cases made from fabrics are hand sewn using heavy-duty threads that do not tear or separate. Stitches are double and triple sewn to ensure a secure and tight material connection.
The assembly of metal tool cases is accomplished in several different ways. The key is to ensure the corners are tightly sealed and that the interior has some form of padding.
Most tool cases are constructed using fabric, metal, and plastic combinations. The processes are combined to create exceptionally sturdy tool cases. In one example, the shell or core of the tool case is made of plastic. Next, the interior is lined with foam cut to the shape of the tools. Finally, the corners of the tool case are reinforced with aluminum.
The example below includes:
An aluminum frame.
Foam inserts.
Heavy plastic walls.
Plastic latches with extra cushioning for the top.
It demonstrates the many factors that are included in a tool case.
Plastics Used to Make Tool Cases
The most common material used for the manufacture of tool cases is various types of plastics with polypropylene, polyethylene, and polystyrene being the strongest and most used. The choice of plastic over other materials is due to its versatility and ability to be formed and shaped into any configuration. Plastic is more durable and can be manufactured using simple processes that do not require elaborate preparations. In addition, plastics are available in a wide range of colors and can be adapted to hold any set of tools from very small precision tools to wrenches and traditional tools.
Polypropylene is used for the manufacture of tool cases due to its chemical, electrical, and fatigue resistance. It is a non-hazard plastic that is one of the most popular plastics that is used for the production of a wide assortment of plastic products. Polypropylene is made from a propene monomer and is the second most manufactured plastic in the world. It can be heated and shaped multiple times in order to achieve a desired form due to it liquifying when heated instead of burning.
Polyethylene is the most used plastic in the world and is made from ethylene. It is very tough, abrasion resistant and can be formed using multiple manufacturing techniques. The versatility of polyethylene is due to the many forms that it takes, which include Ultra- High Molecular Weight Polyethylene (UHMWPE), High-Density Polythene (HDPE), Low-Density Polyethylene (LDPE), and Linear Low-Density Polyethylene (LLDPE). Its different forms are the reasons for its wide use. Of the various types of polyethylene, ultra high weight polyethylene is used for the manufacture of tool cases due its toughness and strength.
Polystyrene is made from the polymerization of styrene and is a stiff, lightweight plastic that can take several forms depending on the application for which it is being used. It is used for the manufacture of tool cases due to its lightweight, resistance to the effects of moisture, and how easily it can be shaped and formed. The stiffness of polystyrene makes it an ideal material for the production of protective tool cases as well as the foam placed inside tool cases. The low cost of polystyrene enables manufacturers to produce tool cases that are inexpensive and durable.
Conclusion
A tool case is a portable case designed to organize and protect tools and allow for easy access and convenient availability.
Many tool cases include ones with a hard outer shell that seals to protect tools from water damage, dirt, damaging liquids, and atmospheric contaminants.
Unlike the toolbox of many years ago, modern tool cases are designed to meet the user's needs specifically. Manufacturers produce tool cases to fit every profession, application, and condition, from ones designed for computer repair to ones capable of carrying tools to repair wellheads on oil rigs.
The choice of tool case materials depends on the tools it will carry and the type of projects or applications where it will be needed.
Critical to the performance of a tool case and how it is manufactured determines the performance and different methods of a tool case and how it is used.
Leading Manufacturers and Suppliers
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