Latest Machinery Used To Manufacture Customised Plastic Cases

design mock up of plastic excellent case with cnc routed foam

Plastic cases are ideal for creating a safe packaging and storage solution for your products or equipment, providing maximum brand exposure as well as a way to keep your products safe and secure.

As expert designers, manufacturers and suppliers of plastic cases, we use the latest machinery to manufacture our bespoke plastic cases so that they can be tailored to any unique requirements. To ensure that our plastic cases are bespoke, we can supply them with custom foam inserts and printed branding or logos.

In this guide, we explain the latest machinery that we use to manufacture our plastic cases and to ensure they meet the exact requirements of our customers.

Waterjet Cutting

Waterjet cutting has become the fastest-growing method of cutting materials as it uses an ultra-high pressure jet of water to cut through the foam cleanly with no dust, cleaning off or sealing required.  Precision cutting by waterjet can produce even the most complex of shapes and narrowest of slots with a reduction in the minimum spacing required between recesses or cut outs to CNC routing or die cutting methods of cutting foam.  

It works by using an ultra-high pressure jet of clean water to cut the foam. The speed of a water jet is so high that it is three times higher than the speed of sound. Water jet cutting is well suited to both large and small quantity projects.  The option to cut stacked materials and use shared edges can offer savings on time and material during the manufacture of large production runs, whilst the lack of the need of expensive tooling makes the process highly suitable for proto-types and smaller quantity orders

Waterjet cutting can achieve sharp hair-pin bends or curves to right angled corners to suit even the most complex of shapes and with the increased cutting depth capability the process offers over die cutting or CNC routing you can be assured you can safely store or transport yours products, tools or equipment.

CNC Router

A CNC router can be used to create recesses at various depths in foam and is useful in creating very complex shapes, which is why it is often considered a favourite choice when creating custom-cut foam inserts for our equipment cases.

As CNC routing is computer-controlled, we use Computer-Aided Design (CAD) to create complex shapes and sizes which are then replicated within the foam using the CNC router. Although, it’s important to first test the design on an off-cut to make sure the CNC router is running smoothly.

To prepare for CNC Routing, we first create the design on our CAD drawing package, which will need to be accurate and to scale. The measurements added to the CAD package will need to take into account the lengths, widths and depths of the shape intended to be cut into the foam. 

Die-Cutting Machine

A die-cutting machine cuts component shapes into foam using a specialist cutting knife, which has to be created using specially fabricated blades. The process is most useful when shapes are needed to be repeated several times, for example, if a bulk order of a large quantity is placed with the same design and custom-cut shapes required throughout.

Many people compare the die-cutting process to that of a cookie-cutter, as these shaped cutters are used to create exact cut-outs to fit tools and equipment. Die-cutting allows us to create customised foam interiors for equipment cases to achieve an accurate and high-quality finish.

In-Mould Labelling Machine

In-mould labelling is a process most suited to higher volume orders and is subject to a minimum order of 1000 labels. The label is moulded into the wall of the case during the manufacturing process whereas most other branding methods are applied to the surface.  In mould labelling can be applied to both the interior or the exterior of the case.

The benefit of using in-mould labelling is that it provides superior resistance to damage to the applied artwork and will allow a digital image or artwork with an unlimited number of colours to be used. While it does take slightly longer to produce cases with IML it is proving an increasing popular choice of branding a plastic case.

Silkscreen Printing

Silkscreen printing is the process of transferring a stencilled design onto our cases by using a mesh screen, ink and a squeegee. The design is imprinted on the case and is ideal for when multiple quantities are needed to be created.

The technique of silkscreen printing produces vivid colours which is why it is ideal for adding branding to cases. With the technique effective in transferring artwork, it’s perfect for applying your company logo to your choice of plastic case.

How can PottertonPacs help you?

Get in touch with a member of our team to discuss how we can help you to create your ideal equipment case with custom foam padding inserts. We will be able to talk you through the process, whilst helping you find the perfect case and customising options that suit you and your specific business needs. 

With one of the broadest ranges of bespoke interior solutions on the market, PottertonPacs are confident we will be able to propose a custom interior solution to suit your needs. We also offer custom cut, fabricated, stitched and moulded interior solutions too.

Get in contact at 0116 276 7562 with any queries or requirements you may have.