This article takes an in depth look at hard cases and their uses.
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A hard case is a durable carrying solution expertly crafted using materials like molded plastic, aluminum, laminated wood, or various metals. These cases are purposely designed to ensure optimal security and robustness. They are equipped with advanced protective features and come in a variety of sizes to accommodate different items. Frequently, hard cases are fitted with wheels for easy transportation and vary widely in dimensions, from compact models to those several feet in both width and height.
Originally, hard cases were the go-to option because of their capability to endure challenging conditions, stress, and possible damage. With the introduction of new materials, soft-sided cases grew in popularity due to their practicality and ease of use. Nevertheless, despite ongoing advancements and innovations in carrying case design, hard cases remain indispensable for their unparalleled protection and durability.
The conventional hard case typically resembles a large briefcase and is commonly used for transporting tools, instruments, and monitors. These cases often feature various organizational elements for easy access and item management. While many people associate hard cases with briefcases, their applications extend far beyond that. They are specifically engineered to meet the rigorous demands of industrial and transport environments.
Hard cases are versatile and can accommodate a wide range of items, from complete sound systems and large wind-measuring instruments to ammunition and firearms. As technology and societal needs have evolved, so has the design of hard cases, leading to continuous innovations and the creation of specialized cases to suit a variety of unique requirements.
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.
Instrument cases are crafted with the understanding that even minor impacts can severely affect the performance of delicate instruments. Consequently, these cases are built to be exceptionally durable, utilizing materials that are both highly resilient and impervious to damage.
Available in various sizes, instrument hard cases typically feature a rectangular shape and are equipped with secure locking latches, robust hinges, and reinforced handles designed for maximum strength and reliability.
Shock mount cases are specialized hard cases equipped with custom inserts designed to absorb and mitigate any impact encountered during transport. These cases feature an additional layer of foam placed between the inner and outer compartments, providing enhanced protection against severe conditions.
The design of shock mount cases is tailored to meet the specific requirements of the customer and the types of materials needing protection. Besides their shock-absorbing capabilities, these cases are also tightly sealed to safeguard against potential water damage, offering an extra level of security.
The ATA has established rigorous guidelines and standards for shipping containers to ensure the protection of items during transit and the safety of materials. ATA cases share a similar structure with standard hard cases but must adhere to specific ATA regulations concerning materials and construction.
Materials approved by ATA include plastic laminates, fiberglass, and aluminum. The inner walls are constructed from multi-layered plywood, reinforced with aluminum abutments bonded with steel rivets. All edges are safeguarded with knuckle ball corners on all eight corners. Long piano hinges are required for hinged lids.
ATA cases feature embedded latches that may be twist spring-loaded or valence spanning spring-loaded. Handles are also embedded to prevent catching or snagging. The interior can be lined with foam options such as 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.
To be categorized as waterproof, a hard case must be airtight, watertight, and resistant to dust and rust. Waterproof hard cases are engineered to endure severe weather conditions and are crafted from high-quality resins that can handle temperatures from -40°F to over 170°F. The hinges and latches are constructed from premium stainless steel or corrosion-resistant plastic to ensure durability against rust and degradation.
Hard-sided computer cases are crucial for safeguarding valuable equipment and data. Laptops represent a significant investment and play a vital role in business operations and record-keeping. Sales professionals rely on them for deal closures, repair technicians use them for tracking service calls and recording customer interactions, and students depend on them for note-taking and work during breaks. Computers are frequently transported in and out of vehicles and placed on various surfaces, making their protection essential.
To shield computers from the rigors of constant movement, users rely on hard cases that not only protect the device but also provide storage for documents, a mouse, charging cables, and other accessories. These cases come in various designs, from those with filing compartments to padded shock-resistant models.
Any impact or shock can potentially damage a computer, leading to data loss or operational failure. Hard cases offer a protective solution, ensuring users can have peace of mind knowing their devices are secure.
Shipping cases are designed primarily to ensure that the contents arrive in perfect condition, providing both protection and security. These cases are constructed from various materials, allowing for the selection of the most suitable case based on the specific requirements of the items being shipped. Similar to other hard cases, shipping cases often include foam inserts for added protection.
One key feature of shipping cases is their ability to absorb shocks and withstand impacts without breaking or splitting. Shipping containers frequently undergo shifts and impacts as they are transported, which can include being jostled, crushed, or struck. Shipping cases are built to endure these stresses, ensuring that the contents remain intact throughout the shipping 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 are essential for safeguarding firearms and preventing damage from impacts and scratches. Firearms are particularly at risk during transport, especially across rough terrains. Regardless of the type of construction, all gun cases aim to shield guns from potential harm. Hard cases, in particular, offer enhanced protection against severe impacts, such as hard drops, rough handling, or being jostled in the back of a vehicle.
Manufacturers have crafted hard cases for a wide range of firearms, from shotguns and rifles to both large and small handguns. Each case typically features shock-absorbing foam padding with custom-cut slots for easy placement of the weapon. Additionally, these hard cases often include compartments for ammunition and cleaning tools.
Gun hard cases come in various sizes, accommodating everything from a single firearm to multiple guns. These cases are meticulously designed to secure the weapon and protect its firing mechanism.
Portfolio cases, especially the hard-sided types, are crafted to simplify the transportation and protection of artwork. They also facilitate the presentation and display of pieces during exhibitions. Given the substantial dimensions of many artworks, these cases come in various sizes, from about 1.5 feet to over 3 feet in length, and feature robust plastic shells with depths starting at one inch.
Hard cases for portfolios offer multiple handle options, including adjustable straps, large handles, and specially designed mechanisms for opening and closing the case.
Tool cases are among the most favored types of hard cases, appreciated for their lightweight nature and ample storage capacity. Their popularity has increased over time, largely due to the practical benefits they offer. While tool cases do not adhere to a universal size standard, those made from blown polyethylene are especially common, valued for their durability, strength, and long-lasting performance.
There is a tool case suited for virtually any repair task, featuring designs with compartments for organizing tools, parts, and instruments. These cases are highly adaptable, catering to the diverse needs of various industries. They can be customized to accommodate any assortment of tools, no matter how specialized or delicate.
Storm cases are similar to shock mount cases, instrument cases, and ATA cases in their design and purpose. They are engineered specifically to safeguard professional tools, equipment, and instruments from severe weather conditions and other potential hazards.
Storm cases feature several protective elements including padlock-compatible latches, pressure relief valves, ergonomically designed handles, and a robust construction that can endure extreme environments. They are designed to be watertight, waterproof, crush-resistant, and dust-proof. Once a storm case is closed and locked, it is virtually impossible to open it without force.
These cases are available in numerous shapes, sizes, and configurations to suit a variety of needs. Most storm cases come equipped with foam inserts for shock absorption and to keep the contents dry and secure.
Catalog cases are designed to function similarly to business briefcases but come with specialized features tailored to their purpose. They are intended to organize and transport sales materials for trade shows, conventions, and presentations. Given the substantial weight of these materials, catalog cases are equipped with extendable handles and robust wheels in addition to standard handles.
Catalog cases may include locking mechanisms and provisions for padlocks, depending on their intended use. Unlike conventional briefcases, they often feature multiple compartments, dividers, and pockets, which are ideal for storing manuals, brochures, pens, computers, mobile phones, and other accessories.
Catalog cases are versatile and can serve various functions, such as storing legal documents for attorneys, organizing presentation materials for sales professionals, or functioning as a compact office space for executives. The efficient organization within a catalog case ensures that all necessary items for a meeting are readily accessible.
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 realm of sample cases, hard cases do more than just provide storage and protection—they also contribute to a company's image and impression. When a representative is set to meet with a client, the appearance and quality of their tools play a crucial role in reflecting the professionalism of the company. A worn-out or poorly maintained hard case can undermine the effectiveness of an initial meeting and potentially harm the company's reputation.
The twelve types of hard cases mentioned are just a glimpse of the extensive range offered by hard case manufacturers. Beyond these examples, manufacturers can design and custom-engineer cases tailored to fit the precise requirements of specific equipment, tools, or applications.
The production of hard cases varies based on the materials used and the manufacturing techniques employed. For metal cases, the raw sheet metal is typically shaped using presses that mold the metal into the desired case form. High-density plastics are shaped through various methods, most commonly involving molds to achieve the final design.
Creating hard cases involves meticulous precision to ensure each product is consistent, sealed, and functional. Given the critical role of maintaining the integrity of these cases, their manufacturing processes are carried out with the utmost care.
Producing plastic hard cases typically involves using a mold shaped to form the case. Depending on the manufacturing technique, plastic can be introduced into the mold in various ways, such as by heating it to make it pliable or by using solid resin pellets.
Rotational plastic molding is employed to create large plastic cases with precise tolerances. This process consists of three stages, all involving the rotation of a mold. The equipment used for rotational molding includes a frame that can rotate along multiple axes, with the mold for the case housed within this frame.
During rotational molding, resin pellets are first placed into the two halves of the mold, which are then sealed securely. The frame, now containing the mold, rotates and is moved into a heating chamber. As the frame turns, the plastic resin melts and spreads evenly across the mold’s interior, thanks to the rotation.
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 full process of rotational molding, or rotomolding, is illustrated in the image below.
Injection molding starts with the same type of plastic resin used in rotational molding. In this process, the resin is fed into a hopper connected to a barrel equipped with a helical screw. As the solid resin pellets move through the barrel, they are gradually pushed along by the screw and heated until they reach a molten state.
At the end of the barrel, the molten plastic is forced through a nozzle into the mold cavity, which is shaped like the final hard case. The plastic is injected under pressure to ensure it fills the mold completely. Once the mold is filled with the required amount of plastic, the product is cooled using water or oil.
The process of demolding, or removing the molded part from the mold, is crucial and must be done carefully to avoid damaging the product. Common demolding methods include ejection and stripping, chosen based on the specific characteristics of the molded item.
Thermoforming differs from processes like rotoforming, blow molding, or injection molding, which utilize melted resin pellets. Instead, thermoforming uses plastic sheets, typically supplied in rolls, that are heated and then molded into the shape of a hard case.
The thermoforming process starts with large rolls of plastic being mounted on the forming machine. The molds used in thermoforming are crafted from high-quality steel to accurately match the shape of the hard case. As plastic sheets are fed into the die, they are heated until they become soft and pliable.
Once the sheets are positioned in the die, its two halves are pressed together to create the hard case shell. After molding, the shape is cooled, trimmed, inspected, and prepared for additional processing.
Thermoforming can be categorized into three types: mechanical, vacuum, and pressure. Although the initial heating process for each is similar, the methods for forming the sheets differ. Vacuum thermoforming uses negative pressure to pull the heated sheet into the mold cavity, while pressure thermoforming applies positive pressure to push the plastic into the mold. Mechanical thermoforming involves using both positive and negative molds that come together to shape the hard case.
Blow molding involves using heated plastic that is inflated with forced air into a mold cavity, creating various hollow plastic shapes. Similar to rotational molding, blow molding ensures that the plastic material is evenly distributed across the mold's surface with consistent thickness.
The blow molding process starts by heating the plastic to create a parison, which is then placed in the mold. Air is blown into the parison under pressure, causing it to expand and conform to the shape of the mold, thus forming 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.
While plastic is a widely used material for manufacturing hard cases, it is not the only option. Metals and wood are also employed in their production, with wood often receiving a veneer or laminate finish to improve its strength, durability, and aesthetic appeal.
The production of metal hard cases starts with metal sheets delivered in large rolls. Aluminum is the most commonly used metal due to its combination of strength and light weight, though stainless steel, carbon steel, and other higher-cost metals are also utilized.
The process begins by cutting the metal rolls into sheets, which are then compressed, bent, and folded to create the shell of the case. An integral part of this process involves attaching a frame to the shell. This frame helps secure and align the four sides of the shell. It is fastened to the shell with steel or aluminum rivets.
To enhance the seal of a metal hard case, the corners are coined, knuckled, and reinforced with additional rivets. Depending on the size, wheels may be added to the corners for easier mobility. After shaping the two halves of the shell, interior features are added, which can include linings made from materials such as rubber, foam, plastic, or fabric.
Alternative metal hard cases may be constructed from sheets that are connected with strips, riveted at the edges, or welded together. These cases are often lined with various materials, with rubber and foam being popular choices. Metal cases of this type come in a wide range of sizes, from briefcase-sized to large shipping containers. Their manufacturing process closely resembles that of wooden cases, which are assembled with wooden panels and components to form a hard case.
Unlike plastic or metal cases, wooden cases are constructed from wooden panels and metal strips, secured with corrosion-resistant crown-topped or domed screws. The assembly process contributes to their lower popularity compared to plastic cases, which are molded from a single piece of solid plastic.
Although termed "wooden cases," these are not solely made of wood. They typically feature a wood veneer or laminate for added strength and durability. Heavy-duty wooden shipping cases often have their edges reinforced with aluminum, steel, or other metals. All eight corners are protected with knuckles, regardless of the edge reinforcement.
Larger wooden cases are equipped with wheels for easier transport. The wooden panels are attached to the metal frame using domed screws, and the lid and frame corners are secured with multiple screws to ensure a robust and secure construction.
The plastic, metal, and wood cases discussed represent just a few of the various methods used to manufacture hard cases. Each manufacturer employs unique, proprietary techniques and continually seeks to refine and enhance their production processes to produce high-quality cases.
Most hard cases are made from thermoplastics, which can be molded and customized to meet various dimensional requirements. In addition to plastics, metals like aluminum are commonly used due to their beneficial properties and versatility.
Materials selected for hard cases must possess essential qualities such as durability, longevity, strength, and resilience. Hard-sided cases are designed to withstand rigorous and challenging conditions without damage or failure, facing stricter demands compared to soft or semi-soft cases.
Polyethylene is a widely used thermoplastic known for its variable crystalline structure, and it is the most produced plastic globally. There are four main types of polyethylene: low density (LDPE), linear low density (LLDPE), high density (HDPE), and ultrahigh molecular weight (UHMW). Among these, HDPE is commonly used for crafting hard cases.
HDPE is favored for its high crystalline structure, which imparts strength, durability, and lightweight properties. It is also resistant to chemicals and can be easily shaped using various plastic manufacturing techniques, making it ideal for hard case production.
Aluminum's numerous properties make it an excellent choice for manufacturing hard cases. It is lightweight, resistant to rust, durable, and easily shaped and configured. Additionally, aluminum can endure exposure to oils, salts, chemicals, and extreme temperature fluctuations.
Aluminum hard cases are typically constructed from various aluminum alloys, as pure aluminum is too soft and pliable for such applications. A significant advantage of aluminum is its non-conductivity, making it particularly suitable for transporting electrical components.
Wood is one of the oldest materials used for carrying cases, having been utilized for centuries to create a diverse range of containers and boxes. Today, wooden cases are often enhanced with coatings like veneers and laminations to protect against scarring, gouges, and other damage.
Among various materials, wood is chosen for hard cases that offer an elegant and aesthetically pleasing appearance, particularly when the natural wood grain is highlighted.
FRP (Fiberglass Reinforced Polymer) is a composite material where fiberglass is used to reinforce a polymer matrix. This anisotropic material has fiberglass particles oriented in a single direction, providing high strength, excellent density, and resistance to corrosion. It also offers favorable electrical, magnetic, and thermal properties. FRP is often used as a substitute for metals when load capacity is crucial, and it is made with fibers such as carbon, glass, and aramid.
The defining feature of a hard case is its exterior, which provides crucial protection, durability, and strength. To maximize its effectiveness, a hard case often includes various add-ons that enhance its functionality and offer additional protection. These add-ons may include zipper cases, pallets, foam inserts, and rubber padding.
Foam inserts provide an additional layer of protection by offering flexibility and shock absorption. They are custom-shaped to fit the items they secure, preventing movement and reducing the risk of impact between items. Foam inserts act as cushioning for delicate and vulnerable materials.
Foam's adaptability allows it to be molded to the exact dimensions of any product. Its exceptional durability ensures that it will maintain its protective qualities for the lifespan of the case.
Pallets expand the storage area within a hard case and enhance organization. They are typically made from various materials and feature sewn pockets from durable fabrics designed to endure frequent use. Pallets can be either removable, functioning like file drawers, or flat and stackable.
The design and functionality of pallets can vary among manufacturers, but they universally serve as an effective solution for organizing tools, devices, instruments, and other essential items.
Wheels have become essential for larger hard cases that carry heavier items. These wheels must be of high quality, designed to support the case's weight and equipped with ball bearings to handle the load. The most common attachment methods for wheels involve screwing or riveting them to the case.
Hard cases equipped with wheels typically require a telescoping handle for easy maneuvering. These handles are integrated into the case, extending and locking into place when needed. They are constructed from materials that complement the case’s design and quality, ranging from heavy-duty aluminum to high-density plastics.
Handles are crucial for a hard case, enabling users to carry, maneuver, transport, and position the case with ease. The common types of handles include:
Standard grip handles, typically attached with screws or rivets, feature a bar design and are usually hinged, allowing them to lie flat against the case. Some hard cases also have embedded handles that fit into a recessed area on the top of the case.
Spring-loaded handles feature a spring mechanism that enables them to retract into the lid when not in use, remaining concealed until needed.
Straps are employed on hard cases to facilitate easier carrying and are commonly found on portfolio cases and those designed for large tools.
Handles are made from three primary materials: metal, plastic, and rubber. Metal handles can be crafted from aluminum, steel, or stainless steel, depending on the case design. High-density plastics are also used, often secured with metal brackets. To enhance comfort, handles may feature foam or rubber coverings or be constructed entirely from rubber.
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