When you spend the time and money it takes to purchase custom hard plastic shipping cases, you expect a quality case inside and out. However, if the case manufacturer just dumps a cheap piece of case foam in your case, you definitely aren’t getting your money’s worth and here’s why.
- Case Foam Varies In Quality
You might think foam is just foam, right? The quality of foam varies, and many manufacturers will use what is known in the industry as “pick and pluck foam.” This type of foam is inexpensive and the quality is poor. Over time, it will break down and basically become useless in terms of protecting your equipment.
At Bel-Air Cases, we create custom foam inserts for all of our carrying cases and hard plastic shipping cases. We use the highest quality foam possible and create custom cavities to fit your equipment perfectly. You’ll never receive a case from us filled with cheap pick and pluck foam.
- Case Foam Is As Crucial As A Tough Exterior
Typically, people invest in custom hard plastic shipping cases because they need to protect expensive items and equipment during transport. We all know how tough the transportation industry can be on cases, which is why your case needs to be built from durable materials and designed to handle impacts.
However, the interior of the case is just as important. High-quality, custom case foam also absorbs impact and holds your equipment in place, so that bumping and jostling won’t affect the items in your case. When you use cheap foam, it doesn’t fully absorb these impacts and the cavities aren’t customized to your equipment so the items in the case get jostled about more than they would with a fully custom case.
- Cheap Case Foam Forces The Customer To Do The Work
When a case manufacturer hands off a case filled with a chunk of pick and pluck foam, the customer is forced to cut away at the foam to create cavities for their equipment. Why should the customer have to do the work? What if the customer cuts away too much foam?
We believe that if you are spending the money on custom hard plastic shipping cases, then you shouldn’t be forced to cut and pick away and create your own foam interior. Additionally, you end up throwing away a bunch of excess foam. Why should a customer have to pay for foam they are just going to toss out? This seems silly, and it’s a huge waste of money and materials.
- Cheap Case Foam Looks Cheap
At Bel-Air Cases, we take pride in creating custom carrying cases and hard plastic shipping cases that are attractive inside and out. If you want a truly professional case, custom case foam is crucial. Not only does it protect your equipment, it just looks more professional.
No matter how carefully you cut away at pick and pluck foam, the end result just looks sloppy. Over time, this foam will begin to break down, as well, which means your case interior will look less and less attractive over time. Our Bel-Air Cases are meant to last for years and years, and still look great as time passes, and that includes the interior.
- Custom Case Foam & Cheap Foam Cost About The Same
It might seem like opting for cheap case foam is highly cost-effective, but that’s just not true. We typically can produce hard plastic shipping cases with custom case foam for about the same cost as you’d pay for a case with cheap pick and pluck foam.
Cheap foam breaks down fairly quickly, and you’ll end up spending more money to replace the pick and pluck foam. Additionally, the cheap-quality foam doesn’t protect your items nearly as well as custom high-quality case foam, which means you may end up with damaged equipment that you must pay to repair or replace. In the long run, spending a few dollars more for a custom foam insert will save you money.
Our Custom Cases
At Bel-Air Cases, our made-to-order custom hard plastic shipping cases are designed using high-density polyethylene plastic. This material is ideal because of its high durability and light weight. It can take the abuse of transport without damaging your equipment, and the light weight helps reduce your shipping costs and makes it easier for customers to handle.
Each case we design can be entirely customized. In addition to a custom exterior size and custom case foam, we can customize the colors, handles, latches, wheels and more. We have a huge selection of custom features, and if you don’t see precisely what you need, we probably can find it. With Bel-Air Cases, it’s all about choice. We also can add in a molded in logo, custom decals or custom engraved plates to elevate the professional look of your case.
Our cases also meet ATA specifications and most MIL specifications. We have designed hard plastic shipping cases for aerospace space companies, as well as the military, so we know how to build cases that can handle just about any situation.
If you need custom carrying cases or hard plastic shipping cases with custom foam inserts, give us a call at any time. We can design cases for audio & video equipment, medical equipment, lighting equipment, military equipment, diagnostic equipment and just about anything else. We’ve been designing cases for more than 50 years, and we look forward to working with you on your case project, whether you need just one custom case, 500 cases or somewhere in between.
At Bel-Air Cases, we are all about customization. Our padded equipment cases can feature a wide variety of locks, latches, feet and handles, as well as molded-in logos, custom decals and much more. But we don’t just customize the exterior of your cases; we also pay special attention to the interior.
Our cases are built to handle the rigors of transport, and while the exterior of your case will absorb the impact and vibrations associated with travel, the custom foam interiors also further absorb the bumps and jostles typical when cases are moving along conveyor belts, tossed into airplanes or bouncing along an interstate in the back of a delivery truck.
Our Custom Foam Interiors
There are many ways that foam can be fabricated, for instance, you can use CNC machining to create custom foam or you can use waterjet fabrication or hot wire fabrication. The type of process that is used depends largely on the end use and the materials that are being used.
For our padded equipment cases, we typically use die-cutting and hand-cutting to craft your foam interiors. Creating a fully custom interior might include creating fabricated interior walls, plastic dividers, interior doors, windows, panel mounts or shock mounts, whatever you need to fully protect and/or display your products.
Our carrying cases often are used as sales kits, for product samples or as OEM cases, and for these types of cases, a custom foam interior might be as crucial as a custom exterior. You truly need a custom interior that shows off your products to their best advantage.
Of course, not every cases needs a fully custom interior with multiple cavities or sections, so we can provide you with a quality foam liner or perhaps layers of quality foam if that’s what you need. It’s all about choice.
What We Won’t Do
While we are happy to customize every inch of your padded equipment cases from the inside out, what we refuse to do is simply hand off a custom case with a chunk of diced foam inside it.
This cheap “pick and pluck” foam is a problem to us on several levels. For one thing, you are paying a premium for a custom case; shouldn’t the interior also be customized? We certainly believe that it should. Typically, we can construct custom foam sets for around the same price that you would expect to pay for a case filled with diced foam.
In addition, with diced foam, the customer is expected to cut and pick away at the foam in order to make cavities. Most of our customers don’t have the complicated die cutting machinery that would be needed in order to create custom cavities, so the end result isn’t exactly attractive or even perfectly designed to protect every inch of your product.
We also object to the idea that the customer pays for a huge chunk of foam and then, after cutting away at it to make cavities, they have to throw half or more of the remaining foam away. Why should customers be forced to pay for foam they aren’t even using? We believe you should only have to pay for the foam that you actually use, which is another reason why we provide custom foam interiors.
Finally, when a company passes off a cheap chunk of diced foam to a customer, this says quite a bit about the level of quality in generally. This foam not only has a less desirable appearance, it also tends to break down quickly and is not as protective in general. If any company tries to sell you a “custom” case but doesn’t also offer to create a custom foam interior, this is a bad sign.
Whether you select Bel-Air Cases or another company, we highly recommend that you select a company with many years of experience (we’ve been here for 50+ years!) that provides you with custom padded equipment cases with a custom foam interior.
Your Case Options
We can design a case for just about any type of equipment and to just about any specification you might need. If you need something that can truly handle transport and rugged environments, our heavy-duty carrying cases and our heavy-duty shipping cases are the perfect options. These cases meet ATA standards and many MIL specs, as well.
In fact, we’ve designed rugged cases for military clients as well as aerospace clients, two groups that truly need cases that can handle just about anything. Our cases can handle impacts and temperature extremes, as well as keeping out moisture and repelling water and various chemicals which might come into contact with your case.
If you want lightweight padded equipment cases that won’t be used as luggage, our light-duty carrying cases are ideal. These are perfect for those aforementioned sales kits as well as OEM cases. If you need a bit more durability, the medium-duty carrying cases can be transported occasionally as luggage.
We also design custom expo cases that are perfect for those oddly-sized items and graphics you need to transport to various trade shows and conferences. These are built to handle the rigors of transport, and we can add wheels and telescoping handles to make it easier to move the expo cases from place to place. Actually, we can add wheels and various handles to all of our cases, to make it as easy as possible for you to carry or move your case through a crowded airport, through a bustling market in Istanbul or perhaps along an uneven path deep in the jungles of Cambodia.
Each Bel-Air Case is designed around whatever will be placed inside, offering you the ultimate level of protection. If you need any type of padded equipment cases, give us a call at any time and we’ll start working on your custom case project.
Whether you need equipment cases with foam to transport lighting equipment, medical equipment, electronics equipment or perhaps a 14th century Ming Dynasty porcelain dragon vase, we can create a custom case that suits your needs.
We design equipment cases with foam for customers in just about any industry. Our cases are completely customized, and we build your case from scratch, based upon agreed-upon specs. Before we start building your case, we consider many factors, including the following:
1. Type Of Transport
We have several different levels of equipment cases with foam – light-duty carrying cases, medium-duty carrying cases, heavy-duty carrying cases and heavy-duty shipping cases. Carrying cases tend to be a bit smaller, and although we call them carrying cases, we certainly can add all types of wheels and handles to make transport as easy as possible.
One of the first questions we ask a customer is how the case will be transported. For instance, our light-duty carrying cases and medium-duty carrying cases are ideal for items that won’t be transported as luggage frequently. While these cases are quite protective, they are meant more for items that might be transported in a backseat or car trunk, and not jostled around by luggage and baggage handlers and bounced along conveyor belts.
For items that you do need to ship frequently, we recommend either our heavy-duty carrying cases or our heavy-duty shipping cases. These cases are built to withstand the rigors of transport and can be shipped or transported as luggage by trains, planes, automobiles, boats or even aboard an Apache helicopter during a combat mission should you need that level of protection.
2. Type Of Equipment
Our light-duty carrying cases and medium-duty carrying cases are ideal for lightweight items that aren’t particularly delicate or expensive, but still are important enough that they deserve a handsome, professional-looking custom case. Light-duty cases often are used to house sales kits, OEM packaging, medical equipment and samples of various lightweight products.
Medium-duty cases are more durable, and can be used as airline luggage on occasion, and these cases are ideal for items that might be a bit more delicate than those packed in a light-duty case, such as diagnostic instruments and electronic devices. These often are utilized for sales kits, as well, particularly if you need just a more protection for the items in the kit or will need to use it as luggage once in a while.
If you do have very delicate and expensive items, or heavier items, even if they won’t frequently transported or shipped, we recommend that you opt for our heavy-duty equipment cases with foam or our shipping cases. These are built using our most durable materials and designed to absorb impact and protect every inch of your equipment.
We use high-density polyethylene for the shells of our cases, which is one of the most durable materials in the world and also provides very high impact resistance. We also use durable aluminum valances and heavy-duty stainless steel hinges. Shipping cases also include molded-in protective corner bumpers and stacking lugs to further absorb impact and protect your equipment. Additionally, these materials are quite lightweight, which makes it easier for the customer to transport and can even reduce shipping costs in general.
3. Equipment Shape & Size
As we stated before, each of our equipment cases with foam is completely custom. We don’t have cases sitting around on the shelf. We don’t build a case until you place your order, so we can design just about any size of case you might need. If you have large or oddly-shaped equipment, we can build a case around it and create a custom foam insert that fits your equipment precisely.
When it comes to equipment cases with foam, we don’t simply build a case and provide you with a chunk of pick and pluck foam. This is a cheap type of foam common in our industry. With this type of foam, the customer has to pick and cut away pieces of foam to create cavities to accommodate your equipment.
Not only does this type of foam not provide a high level of protection, it tends to break down quickly and when you pick away foam, the cavities created aren’t truly custom and your equipment really isn’t fully protected. At Bel-Air Cases, we can create any type of custom foam insert you might need.
We will study your equipment carefully and create the perfect foam insert. We can create anything you might need, from a basic foam liner to complicated designs with plastic dividers, interior doors, windows, panel mounts, shock mounts and more. No matter what you need, we can create the perfect equipment case.
We also offer a variety of decorative options. In addition to our standard colors of silver and black, we also can form your cases in several optional stock colors, including white, yellow, orange, red, olive, green and blue. With a minimum purchase, we also may be able to provide you with custom colors or color matching. We also can personalize your case with a molded-in logo, engraved plates or custom decals.
At Bel-Air Cases, we’ve been creating custom equipment cases with foam for more than 50 years, and whether you need just one carrying case or 100, we can design the perfect case for your needs. To get started, head to our homepage and click on the Request A Quote tab or the Contact Us tab, and we’ll be in touch with you as soon as possible.
Trade shows abound with opportunity, but these can be missed opportunities if you don’t take advantage of the situation. At Bel-Air Cases, we can provide with amazing custom trade show cases, and provide you with a few extra tips for trade show success.
1. Spread The Word As Soon As Possible
Trade shows don’t really start on the morning of the show, you need to building interest in your booth and making contacts long before the doors swing open. Be sure to advertise your presence via social media and generate some excitement. Send out some email blasts or even send handwritten notes to a few potential clients.
Also, don’t forget to spread the word during the trade show. For instance, if you are planning a demonstration or giving away a freebie, get it out there on Twitter and Instagram. If you are hosting an after-hours event, publicize the event before and after it occurs.
2. Create A List Of Goals
Before you head out to any trade show, you and your team need to be clear about the goals of the show. Trade shows can be a big investment, so you want to earn a big payoff. For some companies, that might be closing a set amount of sales, for other companies it might be cultivating a set amount of new leads. In addition to meeting goals, simply having goals makes it easier for your team to develop materials and present their sales pitch more effectively.
3. Build An Amazing Display
Your trade show display can make or break your chances of enjoying a successful event. The design should reflect your product and your customer base. For instance, a booth for the tech industry will look quite a bit different than a booth for the food industry. The same thoughtful approach you used for packaging design should factor into your booth design.
Of course, not every sells a product, and many booths are providing services. The same logic still applies, however, and you want to design a booth that will appeal to your customer base. No matter what you create, keep in mind that you only have a few precious seconds to attract someone’s attention. In many cases, hiring a professional designer can be the way to go.
4. Small Booth? Make A Big Impact
Obviously larger companies probably have a larger budget, but just because you are a hosting a small booth, this doesn’t mean you can’t make a solid impact on passersby. Typically, a small booth includes a backdrop and a table stacked with information, but you could skip the table and instead set up an open space that’s more accessible for clients.
Consider placing items on shelves against the booth wall rather than just displaying items on tables. You might have one small round table at one end of the booth where you can talk with clients, but keep as much of the floor space open so that people can enter and look around.
For instance, perhaps you sell organic beauty products. You might use natural materials to line the back wall of your booth, such as burlap or cotton fabric or even reclaimed wooden pallets. Add some string lights, or bouquets of dried flowers to decorate the top of the booth. Keep your logo visible while creating an inviting, warm ambiance that draws clients into your booth.
5. Provide Thoughtful Giveaways
Giveaways are always a good idea, provided that they will hold some value for potential customers and keep your company in mind even after the show has ended. Reusable water bottles, coffee flasks, flash drives and tote bags are just a few of the many items that can be customized with your company information and used again and again, keeping your logo or company name fresh in mind.
Another option to consider is giving away food or water. Walking the trade show floor can be exhausting, and a candy bar, cookie or bottle of water (all customized for your company) can draw attention to your booth and create a memorable experience for potential new clients.
At Bel-Air Cases, we’ve attended and presented at a fair share of trade shows, and one thing we know for sure, is that our custom trade show cases can make set up, take down and transport a breeze. Our trade show cases are built to withstand the rigors of transport, but also built to accommodate the unique sizes of trade show displays and materials.
Additionally, we can customize each of your trade show cases with custom decals, molded-in logos or perhaps engraved plates. We offer an assortment of stock colors, as well, so that you can order a fleet of cases that will be easy to identify, even on the most crowded trade show floors.
Hard plastic shipping cases can be your best defense against the rigors of transport, but not all cases truly are built to withstand the rigors of transport. In order to select the best possible case options, avoid these common shipping case mistakes.
1. Don’t Opt For Off-The-Shelf
When it comes to general luggage for clothing and personal items, off-the-shelf is perfectly adequate, but when you have to transport delicate or expensive equipment, a custom hard plastic shipping case can be your best friend.
Buy why does custom matter so much? At Bel-Air Cases, we build our cases around your equipment specifications. For instance, when it comes to transporting electronics and computer equipment, we know that jostling and even vibrations can ruin your equipment. Therefore, we design each case so that the case and its foam interior are what absorb impact, and not the items in your plastic shipping cases.
2. Don’t Level Down From Shipping Cases
At Bel-Air Cases, we build shipping cases and carrying cases. Our carrying cases are tough and durable, but our light-duty and medium-duty carrying cases truly aren’t made for frequent transport. They are great when you need to transport something in a car or perhaps in the overhead bin of an airplane, but they aren’t meant for frequent shipping.
While it might be a few dollars cheaper to select a carrying case, if you are going to ship something as freight, it’s in your best interest to spend a little bit more and opt for our heavy duty plastic shipping cases. These cases are constructed from thicker plastic and we use more durable valances and hinges to ensure that they can be tossed, jostled, dropped and generally thrown through the ringer and still protect whatever is inside the case.
3. Never Settle For Cheap Foam
While the outside of your plastic shipping cases obviously needs to be durable, the interior also should match the quality of the exterior. We never simply hand over a case with a chunk of pick and pluck or diced foam. We can provide any level of custom foam interior you might need, from a basic foam liner to inserts with custom cavities, plastic dividers, interior doors, panel mounts and more.
A custom foam interior is crucial, as it cushions and protects every inch of your equipment and absorbs impact. When you are transporting equipment that costs thousands of dollars, opting for custom foam interiors just makes good financial sense.
4. Cases Should Meet ATA Specifications
The airline industry has set certain standards for cases and luggage, and cases that meet these standards are the type you want to select for your equipment. The ATA, or Air Transport Association (now called Airlines for America) does not actually put its stamp of approval on cases, stating whether or not they are ATA approved.
However, at Bel-Air Cases, we build our cases to meet or exceed most ATA specifications. For instance, ATA specifications state that cases should be able to handle temperature extremes of between -40°F up to 130°F. Our hard plastic shipping cases are built to handle temperature extremes between -80°F up to 180°F.
Additionally, ATA specifications should be able to handle drops and other types of impact as well as providing a high level of shock absorption and water resistance. Our heavy-duty plastic shipping cases are solvent, moisture and water-resistant. In fact our cases are able to meet both stringent ATA 300 specifications as well as MIL specifications. You can ship our cases again and again knowing your equipment is well protected and safe.
5. Don’t Pay Too Much
While a cheap $40 shipping case probably won’t offer you the level of protection you need, you also don’t have to spend $1,000 per case in order to ensure that your items are well protected.
At Bel-Air Cases, you’ll find that our prices are quite reasonable, especially given the level of customization we provide. For instance, if you purchase five large plastic shipping cases, you can expect to pay about $400 per case, depending on the features you select.
In addition to customizing the size of your plastic shipping cases, your interior foam and exterior features, such as handles and hinges, we also offer many design customizations. For instance, while silver and black are our standard colors, we also have several additional stock colors and, with a minimum purchase, we may be able to provide color matching. We also can add a molded-in logo, custom decal or engraved plate to your cases, it’s all about choice.
If you need any size of hard plastic shipping cases, contact the team at Bel-Air Cases today. We’ve been creating durable vacuum-formed plastic shipping cases and equipment cases for more than 50 years, and can create whatever you might need, whether it’s just one case or 100 cases.
Can a case be extremely lightweight yet still be durable enough for transport via plane, train or perhaps an automobile navigating a Los Angeles freeway during rush hour? Can a case be stylish and sleek and yet still be able to handle a trek through the jungles of Brazil, a journey across the Sahara desert or perhaps an expedition to Antarctica? If it’s a Bel-Air hard plastic case with foam inside, it’s definitely equal to the task.
If you need a custom hard plastic case with foam inside, we have been the experts for more than 50 years. In fact, we are the first company to create vacuum-formed equipment cases. Our cases are durable, lightweight, affordable and each case is made-to-order, so you’re free to customize everything, inside and out.
The exterior of each case is formed using high-density polyethylene, a durable type of plastic known for its impact-resistance as well as its ability to repel moisture. Cases are joined together using hardy aluminum valances, another material known for its impact resistance and durability.
Of course, we’ve promised you a hard plastic case with foam inside, so let’s talk about the foam. Many case companies simply design a case and provide you with a large chunk of diced foam. Then you have to pick and pluck away the foam in order to create cavities to fit each component or piece of equipment you place in the case.
At Bel-Air Cases, when we build a hard plastic case with foam inside, we create custom foam inserts. This might be as simple as a basic foam liner or it might be a foam insert with multiple cavities, designed specifically to hold each piece of your equipment. We also can include interior doors, windows, panel mounts, shock mounts and plastic dividers for the case interior, depending on your needs.
We can create your hard plastic case using our standard colors of black or silver, and we have several optional stock colors, including blue, green, olive, white, yellow, orange and red. With a minimum purchase, custom colors and color matching may be available. We can further customize your cases with molded-in logos or perhaps with graphics, engraved plates or custom decals.
Of course, you also can customize the handles and hinges and latches or add wheels to your case and even a telescoping handle. While our cases are lightweight, a handle and wheels definitely make it easier to move through a crowded airport, navigate a busy urban street or trek across a huge convention center floor. There’s really nowhere you can’t go with a Bel-Air hard plastic case with foam inside.
Our heavy-duty carry cases, shipping cases and expo cases meet rigorous ATA specifications as well as many military specifications. We’ve designed cases to hold delicate medical equipment, lighting equipment and camera equipment, as well as musical instruments, super-secret classified government documents, sales kits and much more.
With new orders, we typically have a production lead time of about three to five weeks, depending on the order volume and the case options you have chosen. For a hard case with foam inside, it may add to that lead-time. To get started, you can give us a call or click on the Contact Us tab on our homepage, which leads you to our quick contact form. A helpful customer service representative will be in touch with you as soon as possible to talk about your custom case project.
Whether you rock a Fender Stratocaster, a Stradivarius violin or perhaps a vintage clarinet, keeping it safe during your travels is crucial. Custom instrument cases can prevent damage and bring you some peace of mind.
In many cases, musicians will purchase a separate seat for their instrument, particularly if it is a rare, large or extremely expensive item. However, we’ve also read several horror stories of travelers that purchased tickets for their beloved instruments, yet the tickets were revoked because the flight was full or overbooked. Then your instrument ends up tossed around by baggage handlers, which is precisely what a musician does not want.
Additionally, if your instrument is damaged, it can be a huge hassle to receive compensation for these damages. In some cases, airline policy limits the amount of damage compensation they will provide, and it might be far less than the cost of repairs. If you have a vintage or antique instrument, there’s also always the chance that repairs won’t really undo the damage caused by transporting your instrument.
Your best defense is a good offense, and custom instrument cases from Bel-Air Cases can handle the rigors of transportation. Our heavy-duty shipping cases are built to meet or exceed ATA guidelines. These guidelines were created by the airline industry and specify how cases need to be constructed in order to handle the jostling typically inflicted upon them by the transportation industry.
The exterior of our custom instrument cases is built using highly durable the materials. Shells are built using tough polyethylene and the valances are crafted from sturdy aluminum. The case design as well as the materials we use ensure that case itself absorbs any impact and not your precious musical instrument.
Additionally, our custom instrument cases can include a custom foam interior that protects every centimeter of your instrument. We use the highest quality foam for these interiors and never simply stick a chunk of pick and pluck foam inside a case. Pick and pluck foam is a type of low-quality foam that breaks down quickly and doesn’t fully protect your instruments from damage. We never use this type of foam, and, when we design Bel-Air custom instrument cases, every bit of your case is custom inside and out.
Of course, we also can add a bit of flair to your case. We offer black and silver as our standard case colors, but you also can request us to build your case with one of our stock colors, which include white, yellow, orange, red, olive, green and blue. Additionally, we can add a molded-in logo to your custom instrument cases or add engraved plates or custom decals.
We also have many other custom options to consider such as handles, hinges, latches and locks. We can design a custom instrument case with wheels and a telescoping handle to make it easy for you to maneuver through airports, concert halls or wherever else you need to move your instrument.
Using our Bel-Air Custom instrument cases can be the best way to avoid enduring the heartbreak of a damaged instrument. Whether you book a seat for your instrument or check the instrument as luggage, you won’t spend your flight worrying about whether or not your guitar, cello, tuba, violin, clarinet, saxophone or perhaps your mandolin is safe. To start a custom case order, you can click on the Request A Custom Quote tab on our homepage or give us a call at (866) 235-2472.
For more than 50 years, the team at Bel-Air Cases has been providing our clients with custom plastic case manufacturing. In fact, we were the first company in the United States to design, produce and sell vacuum-formed equipment cases.
Our cases are formed using high-molecular weight polyethylene plastic, and we use this specific type of plastic because it’s lightweight, yet durable and strong and able to withstand the punishment the transportation industry may inflict upon it. How do we transform a sheet of plastic into a custom carrying case? It all begins with a conversation.
When clients contact us, we spend some time discussing the type of cases they need. They might need a light-duty carrying case for toting a sales kit or delicate items that won’t be transported as freight or they might need heavy duty cases that can handle trips around the globe with ease. Our first step is to learn everything we can about the items going into the case and how the customer needs to transport it.
Understanding how a case will be transported can be the most important aspect of our plastic case manufacturing. All of our shipping and expo cases are built to handle frequent handling and shipping, as well as our heavy-duty carrying cases. These cases meet exacting ATA standards and many military specifications. Our light-duty cases, however, are not meant to be transported as luggage or shipped. Our medium-duty carrying cases can be used occasionally as airline luggage, but typically, these cases also are better for use as carry-on luggage or perhaps toting items in the trunk or backseat of a car.
Once we’ve determined the type of case you need, it’s time for the next step in our custom plastic case manufacturing process. This includes the selection of case options as well as talking about a custom foam interior. We can create any type of custom foam interior you might need with custom cavities for each component you need to transport, as well as creating panel mounts, shock mounts, interior doors and much more.
We also discuss other custom options, such as case color. Black and silver are the standard colors we use, but we also offer optional stock colors and, with a minimum purchase, we can provide color matching or custom colors. We also can add a molded-in logo to the design or add engraved plates or custom decals.
Once we have a design plan in place, the real fun of plastic case manufacturing begins. We use sheets of thick gauge polyethylene, which are heated to the point where they become malleable. At this point, they are vacuum-forced around a mold or cast, which sucks out all of the air and transforms the plastic into one half of your custom case. The plastic cools and any excess plastic is trimmed away. This whole process actually is known as thermoforming, and it can be used to create thousands of plastic products, from our custom plastic cases to car parts, plastic cups, toys and much more.
Once both halves of your case have been created, we use durable aluminum valances to connect the two halves. Then we add whatever handles, hinges, latches and wheels you may have selected. At the same time, our team of foam experts will be crafting your custom case interior.
No matter what type of custom plastic case manufacturing you might need, the team at Bel-Air Cases is ready to help. Take a look at our different types of cases and then give us a call or fill out our custom quote form which can be found on our homepage. Simply click on Request A Custom Quote, and our friendly customer service representative will be in touch shortly to discuss your custom case needs.
At Bel-Air Cases, we’ve been creating plastic cases with foam inserts for more than 50 years for clients from just about every industry imaginable. Our clients tote medical equipment, musical instruments, camera equipment, computers, lighting equipment, sales kits, trade show materials and much more.
There’s nothing we love more than building custom plastic cases with foam inserts, except possibly for talking and writing about plastic cases with foam inserts. To that end, we’d like to share a few facts about our cases to help you understand a bit about our production process and to help you select the best possible case for your needs.
1. Plastic Is Awesome
Well, we certainly believe that to be true, but many people will ask us why we use plastic for our cases. There are many different types of plastic, and each type has unique properties. We’ve chosen high-density polyethylene for our cases because of its strength, durability and impact resistance. It’s also affordable, easy to mold, and lightweight. And, while your Bel-Air Case is meant to last for years, the plastic we use is even recyclable, so it’s a win for the environment, as well.
2. Aluminum: Another Amazing Case Component
We create the shells of our plastic cases with foam inserts out of polyethylene, but the valances are created out of sturdy aluminum. We chose this material for many of the same reasons we chose our plastic, it’s durable, lightweight and affordable, yet it can handle the rigors of transport again and again. Oh, it’s also recyclable as well, which is just another perk.
3. We Offer Tons Of Custom Features
Nothing about our plastic cases with foam is off-the-shelf, it’s all fully custom. You can add any type of handle, hinge, latch or lock you might want. We offer nine stock colors, but we can provide you with custom colors or color matching (minimum purchases apply). We also can personalize your case with molded-in logos and graphics, or add engraved plates or custom decals. Take a look at all of our case options, and if you don’t see exactly what you want, we can probably get it for you, it’s all about choice.
4. We Have A Case For Everyone
Some of our clients need lightweight carrying cases for sales kits or demo kits, while others need heavy-duty shipping cases that can handle 100 trips abroad with ease. Our light-duty and medium-duty carrying cases are perfect for everything from fragile equipment weighing under 40 pounds that won’t be transported as luggage, while our heavy-duty carrying cases are easy to maneuver yet can handle the rigors of transport.
If you have items that you ship frequently, check out our heavy-duty shipping cases, which have been designed to provide an ultimate level of protection. These rugged, lightweight cases can be created in any size you might need, and we add in molded protective corner bumpers and stacking lugs into each case, ensuring that the case absorb impacts, instead of the case hardware or your components.
5. Heading To A Trade Show, We’ve Got Cases For That
Trade show materials often come in sizes that aren’t compatible with most off-the-shelf cases. Our Expo Cases are the perfect solution, and can be used for wide, lightweight items such as graphics materials, framed pictures and tradeshow components. These cases include easy-roll wheels and heavy-duty spring loaded handles which makes it a snap to maneuver your case through a crowded airport or trade show floor.
6. And, Now, Let’s Talk About The Foam
When we talk about plastic cases with foam inserts, the foam inserts are a huge factor in the design. A foam insert provides an extra layer of protection for whatever you put inside your case, and we can create any type of insert that you might need. We use the highest quality foam and can create multiple cavities to fit each component exactly, as well as creating interior doors, windows, panel mounts and more. For the same price you would expect to pay for cases filled with low-quality foam slabs or diced foam, the team at Bel-Air Cases can create fully custom foam interiors.
Intrigued? Interested? Perhaps fascinated? To learn more about our custom plastic cases with foam inserts, head to our home page and you’ll find links to information about our shipping cases, carrying cases and expo cases, as well as our many custom case options. You also can click on the Request A Quote tab and we’ll get started planning out your custom case project.
When it comes to carrying cases, our customers want something lightweight and easy to transport, but they also want an attractive case, and there’s no reason why your case can’t be both functional and fabulous. If you aren’t sure which type of carrying case to select, here’s some information about our four levels of protection.
Light-Duty Plastic Carrying Cases
These carrying cases are perfect for sales kits, medical kits and demo kits as well as delicate equipment that won’t be transported as luggage. A light-duty carrying case can hold items weighing between five and 20 pounds with ease. Our clients use these cases to hold everything from computer equipment to musical instruments to diagnostic and testing equipment.
Medium-Duty Plastic Carrying Cases
If you do have items that might need to be transported as luggage once in a while, you will want to upgrade to a medium-duty carrying case. If you have equipment or items that weigh more than 20 pounds and up to 40 pounds, but they won’t be transported frequently, a medium-duty case is the perfect level of case for your equipment.
Heavy-Duty Plastic Carrying Cases
If you have heavier items, such as those more than 30 or 40 pounds, or if you need to ship items frequently, but still want the convenience of a lightweight carrying case, our heavy-duty carrying cases are the perfect option. You can ship these cases either as luggage or cargo and they can withstand the rigors of transport, protecting your delicate equipment or whatever you pack inside of them. We create these cases using the same materials and components that we use for our heavy-duty shipping cases, but they are formed on our carrying case tooling, which makes them a bit easier to maneuver in tight quarters.
Custom Foam Inserts
Our fourth case “level” is not a type of case, but rather what goes inside the case. A custom foam insert is an essential component for any Bel-Air Case and we can create everything from a simple foam liner to a complex insert with custom cavities, plastic dividers, interior doors, windows, panel mounts, shock mounts and more.
We use the highest quality foam, and never simply stick in a chunk of diced foam, also known as pick and pluck foam. This type of foam typically is of poor quality and breaks down quickly. We also don’t believe that our clients should have to pick away at foam to make cavities for their equipment, when, for about the same price, we can create a completely custom interior design.
All of our cases include a shell built from durable polyethylene plastic and built with molded-in ribs which absorb impact. We also use steel hinges and a strong aluminum valance for each case. We also can include optional hardware, such as a telescoping handle and wheels, as well as many different types of latches and locks.
Your carrying case, no matter what “level” you select, also can include a molded-in logo or perhaps a custom decal. Standard case colors include silver and black, but we also have several optional stock colors, and, with a minimum order, we can provide you with color matching or a custom color.
No matter what type of carrying case you need, the team at Bel-Air cases can handle the job. We’ve been making quality custom carrying cases for more than 50 years, so just give us a call and we’ll get started on your project, and whether you need one case or 500 cases, you’ll enjoy the same level of quality workmanship and unsurpassed customer service.