Transportation Cases: Durable, Lightweight & 100% Custom |

If you need to frequently ship delicate, expensive gear, purchasing custom transportation cases is the best way to ensure that your items make it from place to place without damage. At Bel-Air Cases, our durable shipping cases can handle the most extreme transportation conditions with ease, and each case is custom-built around your equipment.

In honor of this being our 100th blog article, we thought it might be fun to provide you with 100 facts about our cases, their uses, the materials we use and other pertinent information. Not only will this differentiate us from other case manufacturers, but if you ever end up at a trivia night and have to answer questions about durable, custom shipping cases, you’re all set. So here goes:

10 Facts About Bel-Air Cases

We Originated The Vacuum-Formed Case
Back in the late 1960s, when we were just starting out, plastics were just entering their heyday and we were the first case manufacturers to begin crafting vacuum-formed plastic cases. Vacuum forming is a versatile process that allows the highest level of customization possible. Other plastic cases, such as roto-molded and injection-molded cases, while durable, simply don’t provide the same level of customization.
We Have 50+ Years of Experience
Bel-Air Cases has truly stood the test of time! If you’re searching for a truly reliable case that can handle the rigors of transport, we’ve got you covered. And, in the last 50+ years, we’ve designed cases to hold just about every imaginable item. Our team has the experience and know-how to provide you with custom cases that meet all of your needs.
Our Cases Are Made in the United States
Searching for American-made cases? Our cases are designed and produced here in the United States. We are located in Ontario, California, and are proud to be a manufacturer of quality, USA-made transportation cases. If you’re ever in our neighborhood, feel free to stop by and enjoy a tour of our facilities.
We Have The World’s Largest Library
Ok, to be fair, our library does not contain books. We do, however, have the world’s largest library of standard sizes for thermoformed cases. Of course, if we don’t have your ideal case size in our library, we can create the necessary tooling in-house. With Bel-Air, everything is about customization and quality.
We Don’t Believe In The “Hard Sell”
While we obviously hope that every potential customer selects Bel-Air as their case supplier, we know that we aren’t always a perfect match for every client. There are many different types of cases available, and if we believe a different case type or even an off-the-shelf case is a better fit for your equipment, we will let you. However, if you need to transport delicate and/or expensive items, our cases can be the best option to consider.
Every Bel-Air Case is Made to Order
We do not sell “off-the-shelf” cases; every Bel-Air Case is custom-built to your specifications. This includes the dimensions of the case as well as the foam interior and the case components.
Need an ATA Case? We’ve got you covered
Our heavy-duty shipping cases meet or exceed ATA guidelines, and we also can design cases to meet MIL specifications. If you need cases that adhere to strict military, government or aerospace specifications, just let us know.
We Don’t Offer a Warranty
This surprises many customers, but, honestly, we’ve never needed a written case warranty. We are committed to quality and stand by our cases throughout their lifetime. If something breaks, we will fix it. We know that the transportation industry can put cases through some extreme conditions, so while we cannot guarantee that your case will never incur damages, we will repair those damages for as long as you own your Bel-Air case.
We Don’t Require A Minimum Order
Whether you need just one custom shipping case or a fleet of cases, we are happy to fulfill the order, and we will provide the same level of expertise and customer service for every order, big or small.
We Offer An Exceptional Value
While we don’t sell any cheap $50 cases, our cases won’t break the bank. For instance, if you purchase five large shipping cases, you can expect to pay about $400 or so per case and this includes custom foam interiors. Keep in mind, that our cases provide an ultimate level of protection, ensuring that your delicate gear arrives in good shape every time.

4 Case Types We Offer

At Bel-Air, we have four different equipment case styles available, depending on your needs.

Medium-Duty Carrying Cases
The sleek custom carrying cases are ideal for sales kits, demo kits or OEM cases. While these are durable, they are not built to withstand frequent transport as luggage or freight. If you do need to ship these cases, we recommend boxing them up first.
Heavy-Duty Carrying Cases
If you need the convenience and maneuverability of carry case but also need the durability of a shipping case, our heavy-duty carrying cases are the perfect option. We use the same materials for these cases as our shipping cases, but they are formed on the tooling for carrying cases.
Heavy-Duty Shipping Cases
A Bel-Air shipping case is the gold standard for durable custom shipping cases. These heavy duty cases can handle frequent transport as freight or luggage. Designed with protective corner bumpers and stacking lugs, as well as heavy-duty hardware, our shipping cases provide the ultimate level of protection for your gear.
Trade Show Cases

Our expo cases are designed to hold all of those oddly shaped and sized displays and materials you need for your trade show booth. They feature skate-type wheels and sturdy handles, as well, to make transport as easy as possible.

6 Facts About Vacuum Thermoforming

Vacuum thermoforming is the method we use to form all of our case shells. We love this process for the following reasons.

Precise Shaping with Vacuum Pressure
Vacuum thermoforming uses suction to pull heated plastic sheets tightly over a mold, creating highly detailed and accurate shapes — ideal for making durable and custom-fit cases.
Cost-Effective for Low to Medium Volumes
Compared to options such as injection molding, vacuum thermoforming is much less expensive to set up, making it a smart choice for custom projects or mid-size production runs without huge tooling costs.
Design Flexibility
Vacuum forming can handle complex shapes, and shallow or deep draws, and can incorporate design features like ribs, recessed areas, or custom logos right into the part.
Lightweight, Strong Results
Products made through vacuum thermoforming are often lightweight but strong, offering excellent impact resistance — crucial for protecting valuable contents inside a shipping case.
Durability in Tough Environments
Vacuum-formed plastics can be engineered to withstand extreme temperatures, UV exposure, and rough handling, making them perfect for shipping cases used in industrial, military, or field applications.
Efficient Material Use
Vacuum thermoforming typically produces less material waste compared to other methods, helping reduce both material costs and environmental impact.

10 Facts About Our Case Shells

The shells of our shipping cases, trade show cases and carrying cases are vacuum-formed using high-density polyethylene. We chose this unique type of thermoform plastic for several reasons, including:

HDPE Has an Exceptional Strength-to-Weight Ratio
HDPE is incredibly strong yet lightweight, making our custom shipping cases tough without being too heavy to handle or transport.
HDPE Offers High Impact Resistance
It absorbs shocks and resists cracking under pressure, protecting sensitive equipment during shipping.
HDPE Has High Chemical Resistance
HDPE resists corrosion from chemicals, oils, and solvents, making it ideal for shipping cases exposed to industrial environments.
HDPE Is Waterproof & Moisture-Resistant
HDPE naturally repels water, preventing moisture damage to contents during storage and transit.
HDPE Can Handle Temperature Extremes
It maintains its structural integrity across a wide range of temperatures, useful for both hot warehouses and cold transport environments.
Abrasion Resistance
The surface of HDPE withstands scratches and abrasions better than many other plastics, keeping cases looking professional and extending their usable life.
HDPE Is Non-Corrosive
Unlike metals, HDPE won’t rust or degrade when exposed to saltwater or humid conditions—perfect for maritime or coastal shipping.
HDPE Is Highly Customizable
HDPE sheets can be molded, welded, and cut easily, allowing for the creation of highly customized case designs, sizes, and interiors.
HDPE is Cost-Effective
HDPE has a relatively low material cost, which helps us keep costs down for our customers. HDPE can be molded, welded, and machined efficiently, which also keeps production costs down for us custom case makers.
HDPE Is Recyclable
Our transportation cases are built to last a lifetime; however, HDPE is one of the easiest plastics to recycle, making it an eco-friendly choice for companies concerned with sustainability.

10 Facts About Our Aluminum Valances

While the shells of our custom plastic cases are formed from HDPE, we use aluminum for our valances. Here are some facts about these materials that demonstrate why we selected them for our case valences.

Aluminum Offers Lightweight Strength
Aluminum offers a strong, rigid structure without adding much weight — ideal for keeping the case durable but easy to lift and transport.
Aluminum Has High Corrosion Resistance
Aluminum naturally forms a protective oxide layer, making it highly resistant to rust and corrosion, even in humid, salty, or industrial environments.
Structural Reinforcement
Valances made from aluminum help reinforce the edges and closure points of the case, providing extra stability and impact resistance where it’s needed most.
Precision Fit for Sealing
Aluminum can be precisely machined, ensuring a tight, consistent fit between case halves — crucial for keeping out dust, moisture, and debris.
Aluminum Provides Long-Term Durability
Because aluminum resists warping, cracking, and degradation over time, the valance maintains its strength and functionality for years, even with heavy use.
Aluminum Offers Excellent Temperature Resilience
Aluminum retains its strength across a wide temperature range, protecting case contents whether they’re shipped through cold or hot environments.
Compatibility with Latches & Hardware
Aluminum provides a secure, sturdy surface for attaching latches, hinges, and locks, enhancing the overall security and function of the case.
A Sleek, Attractive Appearance
Aluminum valances give the case a polished, professional look — important for companies shipping high-end equipment or wanting to maintain a strong brand image.
Eco-Friendly & Recyclable
Aluminum is 100% recyclable without losing its properties, making it a more sustainable choice for companies concerned about environmental impact. Again, a Bel-Air Case is meant to last a lifetime, but still love that our materials can be recycled if necessary.
Proven Performance
Aluminum is a trusted material across many industries — from aerospace to automotive — for applications requiring strength, precision, and reliability. At Bel-Air Cases, we’ve used aluminum on our cases for more than 50 years and have found that it truly stands the test of time.

5 Facts About Our Stainless Steel Latches & Hinges

While aluminum is a durable, lightweight option ideal for valances, for our latches and hinges, we opted for an extremely heavy-duty option – stainless steel. Here’s why we chose this material.

Exceptional Corrosion Resistance
Stainless steel resists rust and corrosion even in harsh environments — including exposure to moisture, salt, and chemicals — helping hinges and latches stay functional and reliable over time.
Superior Strength & Durability
It provides excellent mechanical strength, allowing hinges and latches to withstand frequent opening, closing, and impact without deforming or wearing out.
Low Maintenance
Stainless steel hardware doesn’t require painting, coating, or frequent maintenance to retain its appearance and performance, making it perfect for rugged shipping conditions.
Temperature Resistance
It performs well across extreme temperatures, maintaining strength and function whether cases are transported through freezing cold or intense heat.
Professional Appearance
Stainless steel has a sleek, polished look that adds a high-quality, professional appearance to the case — an important touch when the case is used in client-facing situations or high-end applications.

6 Case Options We Can Customize

Aside from the case size and type, we offer additional customization options, including the following.

Choose The Color
Our standard colors are black and silver, but we also offer several additional stock colors, including white, orange, yellow, red, green, olive and blue. With a specific minimum order, we also may be able to provide you with a custom color or color matching.
Add a Personal Touch
We can add custom decals, engraved plates or molded-in logos to just about any case, adding a personal and highly professional touch to your transportation cases.
Select Your Latches
We have a huge selection of latches to match whatever style you like, and if you don’t see the exact component you want among our selections, we can likely source the part you want.
Secure Your Case With Locks
We can provide you with TSA-approved locks or more secure locks if needed, as well as with combination locks.
Wheels, Wheels & More Wheels
Let’s face it a hard case with wheels is much easier to maneuver around a crowded airport or trade show floor, and we can add wheels (we have a huge selection) to just about any case.
Every Case Deserves a Sturdy Handle
We offer a wide range of handle types, including a telescoping handle, which can make transport a breeze.

5 Facts About Our Custom Foam

When we say our cases are 100% custom, we mean it, and this includes the interior foam.

Foam May Be The Most Important Factor
While our exterior shells are built tough, the truth is that a well-designed interior can be more important than the case itself because the foam cushions and protects every item from bumps and vibrations.
Our Foam Offers Precision Protection
Our custom foam is tailored exactly to the shape and size of your equipment, preventing it from shifting during transit. This minimizes the risk of scratches, impacts, vibration damage, or broken components — even during rough handling.
We Use The Highest Quality Foam
At Bel-Air, every custom case includes a high-quality foam interior. Too often, case manufacturers sell cases with cheap pick-and-pluck foam. This cheap foam not only breaks down quickly and customers are forced to cut away at the foam to create cavities for their equipment. The result is a big old mess, and certainly not what you should expect with a custom case. Be wary of any manufacturer that sells you a case with this cheap “pick n’ pluck” diced foam.
Our Foam Provides Enhanced Organization & Efficiency
Custom foam interiors can be designed with specific compartments, making it easy to pack, locate, and access items quickly. This not only protects your equipment but also streamlines setup and teardown times in the field.
We Can Provide Intricate Designs
In some cases, you might simply need a basic foam liner for your case. However, if you need something a bit more complex or wish to display items, such as for a sales kit, attractively, we are experts at foam design. We can create a hard case with foam that includes die-cut cavities, interior walls, interior doors, windows, plastic dividers, shock mounts or panel mounts.

10 Reasons To Purchase Custom Cases

In case it isn’t already apparent, opting for custom cases versus off-the-shelf options includes numerous advantages, including:

Perfect Fit for Your Equipment
Custom cases are built to match the exact dimensions and contours of your items, offering much better protection than one-size-fits-all options.
Superior Damage Protection
Custom cases often include precision-cut foam and reinforced materials, providing enhanced defense against drops, vibration, and environmental hazards.
Protection for Irregular or Fragile Items
If you’re shipping delicate, oddly shaped, or high-value equipment, a custom case ensures every item is supported and cushioned properly.
Optimized Organization
Custom foam interiors allow you to organize multiple components efficiently, making packing and unpacking faster and preventing pieces from shifting or getting lost.
Long-Term Cost Savings
While custom cases may cost more upfront, they can significantly reduce equipment repair and replacement costs over time by minimizing damage.
Enhanced Professional Appearance
A well-designed custom case presents your equipment neatly and professionally, which can be important for client-facing industries like trade shows, media, or medical demonstrations.
Customization for Specific Conditions
Custom cases can be built for specific needs like waterproofing, dust resistance, chemical resistance, or temperature control — options off-the-shelf cases often lack.
Durability & Longevity
High-quality custom cases are built to endure repeated shipping, handling, and tough environments, often outlasting cheaper, generic alternatives.
Security Features
Custom cases can be designed with reinforced locks, tamper-evident seals, and special compartments for extra security during transport.
Branding Opportunities
Custom cases offer the ability to include logos, color choices, and labeling, helping reinforce your brand’s image during transport or at events.

20 Industries That We Can Serve

We can create a case for just about anything from any industry, but here’s a quick list of some of the clients we’ve served in the past.

Military and Defense
Custom shipping cases protect sensitive military equipment, electronics, and weapons during harsh transport and deployment conditions. If you need a military case, our design and production teams can craft a tough, rugged case that can handle a myriad of extremes.
Aerospace
Precision avionics, aerospace components, and testing instruments require rugged cases that safeguard against vibration, impact, and environmental extremes.
Medical & Healthcare
Shipping cases ensure the safe transport of surgical tools, diagnostic devices, and critical medical equipment without risk of contamination or damage.
Telecommunications
Network servers, satellite systems, and communication devices depend on durable cases to maintain integrity during shipping and field installations.
Broadcast & Media
High-value cameras, lighting gear, and sound equipment stay protected and organized in custom cases built for the fast-paced media environment.
Trade Shows & Exhibitions
Companies rely on custom cases to transport delicate booth displays, product prototypes, and promotional materials safely to and from events. Our custom trade show cases are the perfect option for any oddly shaped or oversized expo materials.
Music & Entertainment
Touring musicians and production crews use rugged cases to protect instruments, audio systems, and stage equipment from travel wear and tear. If you are looking for quality custom road cases, our cases are highly protective yet far more lightweight than typical wooden road cases.
Industrial & Manufacturin
Sensitive tools, machinery parts, and precision instruments are kept safe from dust, moisture, and impact in custom-designed industrial shipping cases.
Oil & Gas
Field monitoring equipment, gauges, and testing devices demand protective cases that can withstand rough handling and extreme environments.
Emergency Services (Fire/Rescue/EMS)
Rescue tools, medical kits, and communications equipment are securely transported to emergency scenes using durable, organized shipping cases.
Law Enforcement
Police forces use custom cases to protect forensic equipment, tactical gear, and evidence collection kits during operations and investigations.
Photography & Videography
Professional photographers and filmmakers depend on protective cases to safely carry cameras, drones, lenses, lighting and accessories wherever their work takes them.
Scientific Research & Laboratories
Custom shipping cases are used to move sensitive lab instruments, microscopes, and data collection devices safely between research sites.
Maritime & Shipping
Cases that resist corrosion and water damage are essential for protecting electronics, navigation tools, and equipment used at sea.
Energy & Utilities
Field technicians use shipping cases to transport monitoring instruments, testing tools, and power equipment to remote or rugged work sites.
Automotive & Motorsport
Teams and suppliers transport critical parts, diagnostic tools, and race gear securely in custom cases designed for mobility and protection.
Construction & Engineering
Surveying equipment, laser measuring tools, and delicate electronics are protected from rough job site conditions with heavy-duty cases.
Aviation (Commercial and Private)
Pilots, mechanics, and ground crews use custom cases to move avionics, flight gear, and spare parts safely between aircraft and locations.
Technology & Electronics
Computers, robotics, and high-end electronic systems are safeguarded against static, shock, and environmental hazards during shipping.
Security & Surveillance
Security companies use custom shipping cases to protect and transport surveillance cameras, monitoring equipment, and mobile command systems for field deployment.

14 Facts About 1967

Now that we’ve pretty much exhausted our inventory of facts about our cases, let’s enjoy a quick blast from the past and talk about some interesting historical facts from the year we opened shop – during the wild days of 1967.

The First Super Bowl Kicked Off The Year
It’s hard to imagine a world without Super Bowl Sunday, but the very first Super Bowl was played on January 15, 1967, with the Green Bay Packers defeating the Kansas City Chiefs.
1967 was the “Summer of Love”
While we were busy vacuum-forming cases, thousands of young people flocked people flocked to San Francisco’s Haight-Ashbury district, embracing peace, music, and counterculture. The Monterey Pop Festival also was held in 1967, introducing us to Jimi Hendrix, Janis Joplin and more great artists.
The Beatles Had The Top Album
While the Monkees and the Supremes gave the Beatles a run for their money that year, “Sgt. Pepper’s Lonely Hearts Club Band,” spent 14 weeks at the top of the Billboard album chart.
McDonald’s Upgraded Its Menu
The beloved “Big Mac” was first introduced to the American public in 1967 and quickly ensured our love of “two all-beef patties, special sauce, lettuce, cheese, onions, pickles on a sesame seed bun.”
Andy & Lucy Earned Top Ratings
The Andy Griffith Show and The Lucy Show were the top TV shows of the year, followed by classics such as Gomer Pyle, Gunsmoke and Family Affair. This year also marked a huge surge in the sales of color TVs. The Carol Burnett Show also debuted this year.
Heart Surgery Advanced
The first successful human heart transplant was performed in 1967 by Dr. Christiaan Barnard in South Africa.
Minimum Wage Was Increasing
The national minimum wage increased in 1967 to $1.40 per hour, which is equivalent to about $13.40 today.
Housing & Gas Prices Were More Affordable
Gas averaged out at about 33 cents per gallon in 1967, equivalent to $2.60 in today’s money. The cost of an average house was around $24,000, which is equivalent to about $230,000 adjusted for our current year.
Vietnam Was Raging
It wasn’t all cheap gas and Big Macs – 1967 was a turbulent time. The Vietnam War escalated that year, and massive anti-war demonstrations also began to sweep across the country.
The Times They Were A’Changin
1967 saw the appointment of the first African American justice appointed to the Supreme Court, and the Supreme Court also struck down laws banning interracial marriage.
We Sank Our Battleships
Battleship was a top board game of the year, and other popular toys included Hot Wheels, the Easy Bake Oven, Slinky and Lite-Brite.
The Space Race Was In High Gear
The United States, Soviet Union and United Kingdom signed The Outer Space Treaty in 1967, setting the framework for peaceful space exploration. While that was a positive step, both the U.S. and U.S.S.R. suffered losses.The Americans lost three astronauts due to a cabin fire in Apollo 1 and the Soviet’s Soyuz 1 mission ended tragically when their cosmonaut was killed during re-entry. Still, in just two years, we’d land on the moon in a moment watched by as many as 650 people around the globe.
It Was A Cheesy Year
Fondue became a party sensation in 1967, with thousands of Americans investing in chafing dishes and those cute little forks. Tang, buoyed by its association with NASA and space exploration, was a top drink. Other popular foods included TV dinners, gelatin salads and casseroles.
The Top Movie Was All About Plastics
Ok, not really, but “The Graduate” starring Dustin Hoffman was a top film of the year, and, aside from an exceptional soundtrack, Hoffman’s character was strongly recommended to consider plastics a crucial investment – “I just want to say one word to you. Just one word. Are you listening? Plastics.” We aren’t sure if Hoffman was listening, but at Bel-Air Cases, we sure were, and we knew that plastics would be huge.

Order Custom Transportation Cases Today!

Whether you need rugged shipping cases, carrying cases or trade show cases, the team at Bel-Air is always here to help. To get started on a case project, just click on the Request a Quote tab on our home page and provide us with a bit of information about what you need. A member of our sales team will be in touch to gather information and provide you with a free cost quote for our services.