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Injection Molding
2007-12-05 - EPS
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 Injection molded cases: Plastic resin is melted, once liquefied is then injected into the case tool at extremely high pressure, then cooled with water to a manageable temperature and removed from the case tool when the resin material has hardened. This process works best when there is a need to produce a large volume of cases with the ability to produce very consistent product in both a stock configuration and custom colored of imprinted product. This is the most economical method of producing cases when the need is for hundreds or thousands of cases.
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Rotational Molding
2007-12-05 - EPS
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 Rotationally molded cases: Low, Medium or High Density Polyethylene plastic pellets are ground into a powder and then, combined with color pigment as well as any other additives such as anti-stat or fire retardant materials that might be required, are then added to a case tool. The case tool is mounted on the end of a rotating arm of the roto-mold machine, this arm then goes through a series of stations where the material melts and coats the inside of the slow speed spinning tool. The arm then moves into a water bath area where the case tool is cooled slowly and then finally to a free air spin where the tool is cooled down gradually to room temperature. The tool is then removed from the arm where an entire case emerges only to have the hardware attached and any case interior details added. This process works best when there is a need to produce a smaller quantity of cases from 1-100 pieces. This low stress method of manufacturing produces an incredibly stout case that is imperious to almost all chemicals and is able to take abuse better than anything else on the market. The color is molded throughout the entire case and the material is virtually maintenance free.
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Thermoforming/Vacuum Forming
2007-12-05 - EPS
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 Thermo-formed/Vacuum-formed cases: uses several different types of sheet plastic. ABS, polyethylene and polypropylene are the core case material. Tooling and product turn-around time is fairely quick and cost effective. Depending on the number of case being run, tooling can be made of wood or aluminum. This process starts with the sheet plastic material being heated and then drawn down over the case tool. Depending on the complexity and detail of the case, positive and negative pressure is applied to the material to better emulate the details of the case tool. The molded plastic case shell then goes to the final assembly area where all of the secondary operation like the adding of handles, latches, hinges and valance are added.
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Blow Molding
2007-12-05 - EPS
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 Blow molded cases: Most often molded of High Density Polyethylene which is blown with air pressure against the inside surface of the case mold. The case is made up of a two part tool. Once the part is formed, the tool is cooled with water and the part is removed from the case tool. The molded plastic case shell then goes to the final assembly area where secondary operations like adding the interiors or case labels are added. Most blow molded cases are double wall construction to help add strength to the case. The exterior of the case is textured to hide scuffs and scrapes. Most tools have an area on the lid where a customer can affix a label with either company or product name making the case appear as if they are private labeled.
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Fabricated Plywood Cases
2007-12-05 - EPS
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 Fabricated cases: Are a perfect choice when none of the other cases fit the bill. These cases are assembled one at a time using many different choices of substrate (wall material) ¼", 3/8", ½" plywood, or honeycomb polyethylene plastic, depending on requirement or budget. Fabricated cases are custom made to address the specific needs of the customer. We start off by measuring the equipment going into the case, and then discuss how the customer intends on using the case to come up with the final configuration. We then go to work choosing the proper materials and hardware options to make the case best suit the requirements. We focus on mobility, security and ease of use when coming up with a case solution. All of our fabricated cases meet or exceed the ATA 300 specification, Category 1, which basically means that these cases can be shipped by all types of common carriers and survive a minimum of 100 round-trips while still being functional. Turn around time on these types of cases is usually 2-3 weeks once the configuration is agreed upon.
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Foam Fabrication
2007-12-05 - EPS
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 Custom foam case interiors:
We use many different types of foam depending on several things; how heavy an item is, what type of load bearing surfaces we have to support the item being cushioned, how sensitive an item is to shock and vibration (fragile), is the item static sensitive, is the item moisture sensitive. Besides different densities of foam we also use different types of foam like; Polyester Urethane, Polyethylene, Polyether and more exotic foams like; Cross Link, Expanded Polyethylene, dissipative and anti-stat foam. We design cushions around certain specification so as to provide the utmost protection of your equipment while in the case during storage or transit. We have found most of our customers appreciate the idea of being able to do a "visual inventory" of items in the case very quickly, knowing if anything is missing before getting to the training seminar or tradeshow.
Low quantity interior cushions: These are laid up by hand, typically the items being packed will be put into simple rectangular, square or round cavities in the foam cushion.
Water Jet cut cushions: This is the process of cutting foam using a high pressure water stream. The stream of water cutting the foam is about the same diameter as a human hair so the smallest details are easily cut with great accuracy. The cavity walls are straight at full depth unlike the die cut method which leaves the walls slightly concaved. There is no tooling charge, but there may be a computer programming charge. Waterjet programming is easily changed if a item is added, eliminated or changed within the case cushion. This is a good choice for higher quantities of case interiors. Because the machine is cutting multiple cavities or cushion sets at one time there is a set amount of time to run its computer program.
Die Cut Foam cushions: This custom interior is cut from a steel rule die produced to your exact specifications and is cost effective for purchases of multiple cases that require identical foam interiors. Because the process is very quick this is the most cost effective way of producing a lot of foam cushions. It is very difficult to change any of the cavities and most times the tool has to be remade rather than modified. Tooling is relatively inexpensive especially amortized over the life of the product. The finished product is not quite as nice as a waterjet cut cushion.
Types of foam commonly used:
Polyester/Polyurethane: The most common polymer used to make foam. Polyurethane foam has an elastic cell structure which provides a wide range of performance possibilities. This soft, open-cell foam is best for delicate and light weight items. This is open cell flexible polyurethane foam ranging in density from 1.5# to 6#. It is also available in anti-static formulations.·
Polyethylene: This closed cell foam will not absorb water or moisture. This firm dense foam meets MIL P 26514, Type 1, Class 2 specs. It is generally used with heavier products. It is great foam for positioning and cushioning. Polyethylene is impervious to most chemicals.·
Crosslink/Polyethylene: A rigid polyethylene with little give and is impervious to most chemicals. It is available in anti-static formulations. Crosslink is generally more expensive, but when aesthetics and durability are necessary, they should be considered.
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