Hard Cases: Custom IP67 & ATA Hard Cases for Equipment | Robust Case

Custom Hard Cases for High-Value Equipment: Built to Survive Real-World Abuse

When your equipment costs $5,000 to $500,000 and needs to survive airline baggage handlers, ocean freight, desert dust, and sub-zero temperatures, a soft bag or cardboard box won’t cut it. You need a hard case engineered for your specific gear, your transport environment, and your handling realities.

We design and build custom hard cases in Changzhou’s aluminum case manufacturing cluster — the same region that supplies many of the world’s best-known case brands. Two construction options: rotomolded polyethylene (IP67 waterproof) for harsh environments, or aluminum-framed plywood (ATA-300) for touring and rental fleets. Every case built to your dimensions, with foam cut to your equipment’s exact profile.

Typical FOB: $45–$280/case | 10-year structural warranty | 15–25 day lead time

Hard Case vs. Flight Case vs. Road Case: Which Construction Is Right for You?

The term “hard case” covers three distinct construction families. Picking the wrong one means either overpaying for protection you don’t need, or under-protecting gear that will get damaged.

Feature	Rotomolded Hard Case (Pelican-Style)	Aluminum-Framed Flight Case	Wood & Laminate Road Case
Shell Material	Rotomolded LLDPE polyethylene	9mm plywood + aluminum extrusion frame	7–9mm plywood + PVC/ABS laminate
Water/Dust Rating	IP67 (submersible 1m for 30 min)	IP54–IP65 (splash/dust resistant)	IP40–IP54 (basic splash)
Weight	Heavy (8–25 kg empty)	Medium (5–15 kg empty)	Light (3–10 kg empty)
Impact Resistance	Excellent (monolithic shell absorbs energy)	Very Good (frame distributes load)	Good (laminate + corner blocks)
Custom Foam	CNC-cut PE or polyurethane foam	CNC-cut PE foam + egg crate	PE foam + carpet lining
Typical Price (FOB)	$80–$350 (medium size)	$60–$250 (medium size)	$40–$180 (medium size)
Best For	Military, medical, outdoor, ocean freight	Touring, broadcast, rental fleets	Local transport, studio gear, budget
Stackability	Excellent (interlocking design)	Good (flat top/bottom)	Fair (varies by build)

Typical FOB Price Ranges (Shanghai Port)

Pricing depends on size, construction, foam complexity, and quantity. These ranges give you a realistic starting point for budget planning:

Case Size (External L×W×H)	Rotomolded IP67	Aluminum-Framed	Wood & Laminate
Small (300×250×150mm)	$45–$80	$35–$65	$25–$50
Medium (500×400×250mm)	$80–$160	$60–$120	$40–$90
Large (800×600×400mm)	$160–$320	$120–$250	$80–$180
X-Large (1200×800×600mm)	$320–$600	$250–$450	$180–$350

Prices are FOB Shanghai per unit, based on MOQ 50 pieces. Custom foam, wheels, colors, and branding are additional. Volume discounts available for 100+ piece orders.

Who Are These Cases For?

Our hard cases serve six primary customer segments, each with distinct protection requirements:

Customer Type	Typical Equipment	Key Protection Needs	Recommended Construction
Touring & Rental Companies	Line arrays, mixing consoles, LED walls, microphones	Repeated handling, stackability, quick access	Aluminum-framed flight case with caster board
Medical Device Makers	Ultrasound, endoscopy, portable diagnostic, calibration gear	Temperature control, shock isolation, sterile-compatible foam	Rotomolded IP67 with custom PE foam
Military & Defense	Optics, communications, drone components, test equipment	MIL-STD-810H compliance, EMP shielding, CARC coating	Rotomolded with pressure equalization valve
Industrial & Field Service	NDT equipment, gas detectors, calibration tools, power analyzers	Drop protection, dust resistance, tool organization	Aluminum-framed or rotomolded with custom compartments
Broadcast & Film	Cameras, lenses, lighting, monitors, DIT stations	Shock isolation for optics, quick-access lids, cable management	Aluminum-framed flight case with foam-lined compartments
Aerospace & Defense Contractors	Avionics, satellite components, ground support equipment	ESD protection, humidity control, traceability	Rotomolded IP67 with ESD-safe foam and desiccant ports

How We Build Your Hard Case: Construction Specifications

Every hard case we build starts with your equipment’s dimensions, weight, and transport environment. We don’t sell off-the-shelf boxes — we engineer protection around what you actually ship.

Rotomolded Hard Cases

• Shell: Linear low-density polyethylene (LLDPE), 4–6mm wall thickness, rotomolded in a single piece
• Sealing: Continuous silicone or EPDM gasket, IP67 rated when latched
• Latches: Stainless steel or ABS trigger latches, padlockable (2 points)
• Hinges: Full-length stainless steel piano hinge or integrated polymer hinge
• Pressure Valve: Automatic Gore-Tex or equivalent pressure equalization valve (standard)
• Handles: Rubber over-molded top handle, optional side handles for 2-person carry
• Wheels: In-line skate wheels or heavy-duty casters (optional, for cases over 15kg)
• Foam: 40–60 kg/m³ polyethylene (PE) or 30–50 kg/m³ polyurethane (PU), CNC-cut to your equipment profile
• Custom Colors: Black, olive drab, desert tan, safety orange, or custom RAL color (MOQ applies)

Aluminum-Framed Hard Cases

• Panels: 9mm multi-ply birch plywood, laminated with ABS or PVC in your choice of color/texture
• Frame: Anodized aluminum extrusion (1.5–2mm wall), riveted or screwed construction
• Corners: Galvanized steel or aluminum corner protectors, riveted at all 8 corners
• Edges: Aluminum edge trim on all exposed edges
• Latches: Butterfly or draw-over latches, padlockable
• Hinges: Stainless steel piano hinge (full length)
• Handles: Spring-loaded surface-mount or recessed rubber handles
• Wheels: Caster board with 4× 100mm wheels (2 locking, 2 swivel) or inline wheels
• Foam: 40 kg/m³ PE foam base + 25 kg/m³ egg crate lid, CNC-cut to equipment profile

Custom Hard Cases for High-Value Equipment: Built to Survive Real-World Abuse

When your equipment costs $5,000 to $500,000 and needs to survive airline baggage handlers, ocean freight, desert dust, and sub-zero temperatures, a soft bag or basic cardboard box won’t cut it. You need a hard case engineered from the ground up for your specific gear, your specific transport environment, and your specific handling realities.

We design and build custom hard cases in Changzhou’s aluminum case manufacturing cluster — the same region that supplies many of the world’s best-known case brands. Every case is built to your dimensions, with foam cut to your equipment’s exact profile, and tested against the standards that matter for your industry.

What Happens When You Don’t Use a Proper Hard Case: Real Damage Costs

We’ve seen the same damage patterns repeat across industries. Here’s what inadequate protection actually costs:

• Drop damage (34% of shipping claims): A 1.2m drop onto concrete generates 80–150g of impact. A $12,000 camera lens with a cracked internal element costs $3,500 to repair and 4–6 weeks of downtime. A hard case with 50mm PE foam reduces transmitted force to under 15g.
• Vibration fatigue (28% of claims): Truck transport generates 5–20Hz vibration at 0.5–3g acceleration. Over a 10-day cross-country haul, this equals 8.6 million vibration cycles. Loose connectors, cracked solder joints, and misaligned optics are the result. Custom foam with tuned stiffness isolates equipment from resonant frequencies.
• Water intrusion (12% of claims): Ocean freight containers can experience 90%+ humidity and occasional water ingress. A $45,000 ultrasound machine with water-damaged circuit boards costs $12,000 to repair. An IP67 rotomolded case eliminates this risk entirely.
• Compression damage (18% of claims): Airline cargo holds stack bags 3–4 high. A 30kg case on top of yours exerts 300N of force. Weak cardboard or thin plastic collapses. A rotomolded shell supports 500kg+ of static load without deformation.
• Downtime cost (often bigger than repair): A touring band missing a $8,000 mixing console loses $15,000–$50,000 per cancelled show. A field service engineer without their $5,000 calibration tool bills 0 hours that day. Protection isn’t just about repair cost — it’s about revenue protection.

How to Order: 5 Steps from Drawing to Delivery

1. Send us your equipment details. Dimensions (L×W×H), weight, fragility level, transport method (air/sea/road), and quantity. Photos or CAD files help us understand access points and protrusions.
2. We propose a construction and foam layout. Within 3–5 business days, you’ll receive a case specification with dimensions, material list, foam layout drawing, and FOB price. No charge for this initial proposal.
3. Approve the design and place your order. Once you confirm, we cut a foam prototype (for complex layouts) and send photos for your approval before full production.
4. Production and quality inspection. Standard lead time: 15–25 working days for first order, 10–15 days for repeat orders. Every case is inspected for dimensions, foam fit, hardware function, and seal integrity before packing.
5. Shipping and delivery. FOB Shanghai or EXW Changzhou. We can arrange sea freight (LCL/FCL), air freight, or express courier (DHL/FedEx) depending on your timeline and budget.

Installation & Setup: How to Get Your Equipment In and Out

Every hard case we build is designed for quick, tool-free access to your equipment. Here’s how the typical setup works:

• Equipment insertion: Lift the lid (spring-loaded hinges hold it open at 90°), place your equipment into the CNC-cut foam cavity, and press firmly until it seats. The foam is cut to ±1mm tolerance, so equipment goes in snug but doesn’t require force.
• Cable management: For cases with cable pass-through ports, route cables through the gland plate before closing. All ports are IP67-rated when mated.
• Stacking: Rotomolded cases feature interlocking ribs on top and bottom. Stack up to 4 high (max 200kg total load) without slipping. Aluminum-framed cases have flat tops for stable stacking.
• Wheeled transport: Cases over 15kg ship with a caster board or inline wheels. Telescoping handles are available for frequent single-person transport.
• First-use inspection: Before putting your case into service, check that all latches click shut, the gasket is clean and undamaged, and the pressure valve (if equipped) moves freely.

Foam replacement: If your equipment changes, we can supply replacement foam inserts for your existing case shell. Send us the new equipment dimensions and we’ll cut a fresh foam set — no need to buy a new case.

What If Something Goes Wrong? Warranty & Support

We stand behind every case we build. Here’s exactly what happens if you encounter a problem:

Issue	Response Time	Resolution
Damaged on arrival	Within 24 hours of report	Photo inspection → replacement parts shipped free / full case replacement if structural
Foam doesn’t fit	Within 48 hours	Re-cut foam set shipped free (we keep your foam CAD file on record)
Latch/hinge failure	Within 5 business days	Replacement hardware kit with installation instructions (field-replaceable, no tools needed)
Custom modification needed	Quote within 3 business days	Modify existing case or build new foam insert; shell can often be reused
Bulk order quality issue	Within 24 hours	Root cause analysis → corrective action → replacement shipment at our cost

Structural warranty: 10-year warranty against defects in materials and workmanship on the case shell, frame, and hardware. Foam inserts are warranted for 2 years against premature wear under normal use.

Serial number tracking: Every case gets a unique serial number laser-etched or riveted on. Register your case with us and we’ll keep your foam CAD file, order history, and warranty status on record — making reorders and replacements fast and accurate.

Support channels: Email [email protected] (response within 12 business hours) or WhatsApp +86 176 2594 7792 for urgent issues. We’re available Monday–Saturday 8:30AM–6:00PM GMT+8.

Compliance and Standards

Our hard cases can be built to meet or exceed the following standards, depending on your requirements:

• ATA Spec 300 Category I: 100+ handling cycles, minimum 9mm plywood, steel corners, full-length hinges
• MIL-STD-810H: Drop, vibration, humidity, salt fog, and temperature shock testing protocols
• IP67: Dust-tight and protected against temporary immersion (1m, 30 minutes)
• ISTA 3A: Package performance testing for individual parcel delivery systems
• ISPM-15: Heat-treated wood packaging for international shipping (stamped and certified)
• RoHS / REACH: Materials comply with EU environmental regulations

Custom flight cases engineered and produced in Changzhou’s aluminum case manufacturing cluster. OEM/ODM with partner factories operating under ISO 9001 quality systems.

Ready to Protect Your Valuable Equipment?

Get a free custom case quote within 3–5 business days. Send us your equipment dimensions and we’ll handle the rest.

Request a Free Quote →

Email: [email protected] | WhatsApp: +86 176 2594 7792
Changzhou, Jiangsu Province, China | Mon–Sat 8:30AM–6:00PM GMT+8

Further Reading

• Custom Flight Cases for Touring & Rental
• Custom Road Cases for Touring & Rental
• Custom 19-Inch Rack Cases (Shock Mount & Rolling)
• Custom Equipment Cases for Industrial & Scientific Instruments
• Custom Cases: Built for Your Exact Equipment
• ATA Flight Cases: Category I Spec 300 Touring Cases
• Protective Cases: Custom IP67 & ATA Cases for Equipment
• Shipping Cases: Custom ATA & IP67 Cases for Global Transport
• Flight Case Cost Calculator