Real Projects. Real Protection.
From tactical weapons cases to precision drone transport — see how we solve complex foam insert challenges.
Drone · Weapons · Precision Instruments
Military-Grade Tactical Drone Transport System
A defense contractor needed to transport 6 DJI Matrice 300 RTK drones plus accessories in a single flight case. Standard foam couldn't accommodate the irregular arm geometry and fragile gimbal systems.
- ✕ Drone arms and gimbals damaged during air freight — 12% damage rate
- ✕ No foam could accommodate the complex folded-arm geometry
- ✕ Batteries and controllers mixed with drone bodies — ESD risk
- ✕ No military-grade case available off-the-shelf
- ✓ 3-layer EVA foam system: drone bodies / gimbals / accessories
- ✓ ESD anti-static foam layer for batteries and electronics
- ✓ Precision-cut arm slots at ±0.5mm — zero movement in transit
- ✓ Custom aluminum flight case with military butterfly locks
Zero damage across 40+ international flights. Client reordered 12 additional sets for their full fleet.
Tactical Rifle & Handgun Transport Foam Insert
A European law enforcement equipment distributor required foam inserts for tactical cases — each holding 2 rifles, 4 handguns, suppressors, and cleaning kits. The foam needed to meet airline transport regulations.
- ✕ No standard foam fit the irregular shapes of rifles and suppressors
- ✕ Weapons shifting in transit — safety and damage risk
- ✕ Failed IATA dangerous goods packaging requirements
- ✕ Local suppliers couldn't meet the precision requirements
- ✓ Custom die-cut PE foam with CNC routing for each weapon profile
- ✓ Black top foam + bright orange base layer for visual inventory check
- ✓ Separate compartments for suppressors, magazines, cleaning kits
- ✓ Passed IATA dangerous goods transport regulations
Adopted as standard issue for 3 police departments. 200+ cases delivered across 8 European countries.
Total Station & GPS Survey Equipment Case
A surveying equipment rental company was losing $15,000/year to damaged total stations and GPS receivers. Generic foam cases didn't fit the irregular tripod heads and prism poles.
- ✕ $15,000/year in equipment damage during site transport
- ✕ Generic foam didn't fit total station geometry — instruments shifted
- ✕ No separate compartments for prism poles and data collectors
- ✕ Quick field access impossible with poorly designed inserts
- ✓ High-density EVA foam with 8 custom-fit compartments
- ✓ Color-coded foam layers for instant inventory verification
- ✓ Vibration-absorbing density selected for vehicle transport
- ✓ Quick-access top layer for most-used instruments
Equipment damage dropped to zero. ROI achieved in 2 months. Client expanded to 15 case sets.
Tools · Flight Cases · Luxury Packaging
From Scratched Tools to Zero-Damage Delivery
A German tool brand needed custom foam inserts for their premium hand tool sets. Generic foam was causing tools to shift and scratch during shipping.
3,000+ units shipped — zero damage reports. Customer reordered 3 times.
Flat-Pack Flight Case Kit — Solving the Shipping Cost Problem
An Australian AV equipment supplier wanted custom flight cases but couldn't afford the high shipping cost of assembled cases from China.
Shipping cost reduced by 65%. Customer now orders 50 kits per month.
Premium Flocked Foam for High-End Gift Packaging
A Hong Kong luxury gift brand needed foam inserts that matched their premium brand positioning — standard foam looked cheap and didn't fit their products.
Brand elevated their unboxing experience. Now using our foam across 12 product lines.
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