Hard Cases fall into (3) General Material Categories:

• Fabricated
• Plastics (Based on Molding Method):
  • XLT & Corrugated Plastics
  • Blow Molded
  • Injection Molded
  • Rotomolded
• Aluminum

The material of your case will depend on several different factors such as transport and environmental requirements, in addition to durability requirements, product capabilities, and size and weight of contents. Cases2Go offers a variety of case materials and configurations to meet your specifications. Below is a general guide to each type of material, including the pros and cons of each. Should you have additional questions, our sales specialist will provide the most appropriate product to compliment your application requirements.

1.) Fabricated

• Fabricated cases are made at time of order
• Average lead time is 7-14 business days, standard sizes may be available
• Constructed of either (a) plywood w/ ABS laminate covering or (b) XLT plastic
• Manufacturers Include:
  • Anvil
  • Calzone

Pros:

• Cases are made to size, or in other words, around the contents
• Limitless configurations and sizes
• Custom configurable dimensions (inside or outside) to meet requirements
• Hard partitions are available to keep items in place or strengthen case
• ATA Rated

Cons:

• Heavier
• Water resistant. Not waterproof. 
• Not as resilient (materials ability to recover from shocks or blows) as plastics

2.) Plastics

• Plastic by nature will absorb impact.
• Types of Plastic Cases (Based on Molding Method):
  
  
  • XLT & Corrugated Plastics: Produced from Polypropylene resin with a similar make up to corrugated fiberboard. Two layers of polymer are connected by flutes to form a sturdy sheet of material which has a wide range of uses. The result is a lighter weight and more rigid plastic.
    • Can also be defined as "fabricated"
    • Comes in (3) Thicknesses: 1/4", 1/2", and 3/8" construction
    • Polypropylene plastic
    • Manufacturers Include:
      • Anvil
      • Calzone

Pros:

• Material is 30% lighter inch for inch.
• Will not splinter like plywood
• More Resistant to Environmental wear (ie: Humidity and Water Damage)
• ATA Rated
• Milspec Rating Available
• Lockable

Cons:

• Size Limitations – will show “Give” unlike plywood as length is increased
• Blow Molded: Also known as “blow forming”, is a manufacturing process by which hollow plastic parts are formed. The basic process has two fundamental phases. First, a preform (or parison) of hot plastic resin in a somewhat tubular shape is created with a hole in one end which compressed air can pass through. Second, a pressurized gas, usually air, is used to expand the hot preform and press it against a mold cavity. The pressure is held until the plastic cools. This action identifies another common feature of blow molded articles. Part dimensional detail is better controlled on the outside than on the inside, where material wall thickness can alter the internal shape.
  • Manufacturers Include:
    • Platt Luggage (Over 60 Standard Sizes)
    • Blow Molded Products

Pros:

• Standard sizes offer an economical solution for light duty requirements
• Custom blow molded cases offer a unique advantage that allows the flexibility of forming the plastic around the contents. Foam cushioning is not required.

Cons:

• Light duty product - This product IS NOT recommended for shipping
• High volume required for production of custom sizes 

• Injection Molded: Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity. With Injection Molding, granular plastic is fed by gravity from a hopper into a heated barrel. As the granules are slowly moved forward by a screw-type plunger, the plastic is forced into a heated chamber, where it is melted. As the plunger advances, the melted plastic is forced through a nozzle that rests against the mold, allowing it to enter the mold cavity through a gate and runner system. The mold remains cold so the plastic solidifies almost as soon as the mold is filled.
  • Manufacturers Include:
    • Hardigg Storm
    • Pelican™
    • SKB Music Cases

Pros:

• Shorter Lead times, most manufacturers carry stock of various sizes and colors.
• Light Weight and Rigid
• Standard Sizes are an economical solution for medium duty requirements.
• Airtight, watertight standard configurations
• Field repairable hardware
• Color is molded in
• Custom Colors available for volume orders
• Pad-lockable
• ATA & Milspec Rated

Cons:

• Size Limitations, Larger contents will require a fabricated or rotomolded case due to load capacity.
• An initial mold for custom sizes can be expensive
• Walls are Thinner
• Standard Color Selection is limited 

• Rotomolded: A heated mold causes the plastic powder material within to melt and form a puddle at the bottom of the mold cavity. The mold is then slowly rotated (usually around two perpendicular axes) causing the melted material to flow into to the mold and stick to its walls. In order to maintain even thickness throughout the part, the mold continues to rotate during the cooling phase.
  • Production time requires 45 minutes per case
  • Polyethylene Plastic
  • Manufacturers Include:
    • Hardigg
    • SKB Music Cases

Pros:

• Unlimited Size Constraints
• Can “create” new size using the “cut & weld” process (Case is cut in half, a center section is welded in)
• Resilient - Offers heavy duty solution for shipping and transit
• Recessed hardware (latches & hasps)
• Chemically Inert
• Airtight and Watertight configurable
• Over 300 standard sizes
• Color is molded in
• Pad-lockable
• ATA & Milspec Rated

Cons:

• Heavier
• Average lead time is 4-6 weeks

3.) Aluminum

• Manufacturers Include:
  • ZARGES
  • ZERO

Pros:

• Extremely Strong - 50,000 lbs per inch of tensile strength
• EMI Shielding available
• Lighter in weight
• Waterproof
• Material is not sensitive to extreme temperature fluctuations - hot to cold - the material characteristics remain the same
• Machinable - Customizable sizes and configurations available
• Painting, anodizing, etching and embossing is available
• Hygienic, Sterilizable and Decontaminable
• Recyclable Material
• ATA & Milspec Rated
• UN & IATA Certification Available

Cons:

• Will show scratch and dents, however does not indicate weakness
• May be more expensive than plastic or fabricated cases
• Excessive heat may cause difficulty in handling metal surfaces, painting or coating may be required.