Category Archives: Case Foam

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.

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.