This article takes an in depth look at road cases and their use.
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A road case is a robust and durable protective container designed to endure the challenges and rough handling associated with shipping. It features varying wall thicknesses to provide resilience against impacts and stress, making it suitable for cargo plane or commercial transport requirements.
Typically, road cases are constructed from high-quality black laminated plywood, complemented by recessed steel handles, aluminum edging, and steel-corner protection. They offer a range of interior configurations tailored to the specific needs of the contents they house.
Premium road cases are engineered to shield their contents from impacts, collisions, extreme temperature fluctuations, shocks, vibrations, dirt, dust, and moisture. Besides providing protection, road cases ensure that instruments and devices remain secure and well-cushioned during transport, thanks to inserts made from robust materials like specialized foams and rubber.
Road cases are crafted to safeguard and secure equipment during transit, ensuring it arrives in a ready-to-use condition. These cases are built from durable materials that are meticulously chosen and engineered. Proper planning is essential for shipping, storing, and accessing equipment from a road case.
Fortunately, road cases come in a vast array of sizes, designs, and configurations to accommodate any type of instrument, device, or equipment. This extensive variety is a key reason why road cases are trusted for their protective and safety capabilities.
Ramp road cases are a specialized category of road cases that feature an integrated ramp for convenient loading of equipment on casters. These ramps come in various designs; some are flat wooden panels, while others are track systems that are stored beneath the case and extend when needed.
These cases are particularly well-suited for transporting, storing, or moving small generators, delicate medical equipment, or portable workstations. In addition to the different ramp designs, ramp road cases are available in several configurations, with many being custom-designed to meet specific application needs.
A workstation road case is a mobile tool cabinet featuring a flat top surface and an upright back designed to hold tools, monitors, and other electronic devices. These cases come equipped with various accessories, including worktables, shelving, electrical outlets, and different sizes of work surfaces. Typically custom-built to meet specific customer needs, workstation road cases can also house complete recording or video production systems.
Due to their versatility, workstation road cases are particularly well-suited for use in disaster relief operations, mobile immunization stations, and portable hospitals. Their design allows all components to be neatly organized within drawers and compartments for easy access and storage.
Trunk road cases are versatile, general-use cases available in various sizes. They are built with standard features such as recessed latches, steel corners, wood-backed laminate, and spring-loaded latches. The main difference among trunk road cases lies in the types of inserts used, which are tailored to accommodate the shape of the items being transported.
Historically, the American Transportation Association (ATA) established standards for road case specifications. This organization has evolved into the Airlines for America (A4A), which now utilizes the ATA's standards for road case approval.
A4A road cases represent the highest level of protection, designed to withstand the most extreme and challenging conditions. They are built to adhere to the stringent A4A standards, which mandate that these cases endure 100 trips without experiencing any failures or damage.
To comply with A4A standards, a road case must successfully undergo a series of rigorous tests, including drop, water spray, and vibration tests. The A4A has detailed protocols for each test, and manufacturers must strictly follow these guidelines to achieve A4A certification.
Rack mount road cases are another form of specialty case designed for the shipping and storage of equipment from fixed racks. They can be set up indoors or outdoors, depending on the demands of an application. The convenience of rack mount cases makes it possible to operate the protected equipment without removing them from its case. They are made from a variety of materials including laminated plywood, rotomolding, and injection molding.
Workbox road cases are designed as work cabinets equipped with multiple drawers for the secure storage of components. They offer convenient access to work materials and are available in various sizes, with different drawer counts, heights, mobility features, and handle options. Due to their weight, all workbox road cabinets are fitted with casters. A padded door is installed over the drawers during transit to prevent them from opening.
Plywood is typically used in the construction of workbox road cases due to their dimensions. These cases feature aluminum L brackets on their edges, with knuckle or flat brackets at the corners. U-shaped aluminum channels provide support for the door, drawers, and the cabinet's base.
Road cases are produced using various methods, including rotational or injection molding and fabrications from metal and wood panels. Typically, large and complex cases, such as rolling cases or trunks, are created through fabrication, whereas smaller cases often utilize one of the molding techniques. Regardless of the manufacturing process used, all road cases are designed to be highly rugged, durable, and strong, ensuring reliable protection and longevity.
Road cases are constructed using two primary types of rivets: blind and split. Both types are accompanied by washers to prevent loosening or movement. Blind rivets create a more robust and secure connection compared to split rivets, though they generally come with a higher cost and longer installation time.
Blind rivets, also referred to as pop rivets, are utilized in situations where the rear side of the joining surfaces is inaccessible. The rear side is known as the blind side. The top portion of a blind rivet, or the body, is attached to the stem. The rivet is placed through a hole in the materials to be joined. Using a riveting tool, the body is expanded, allowing the stem to be detached, which results in a secure joining of the two pieces.
Split rivets, also known as bifurcated rivets, are a type of self-piercing rivet featuring two tails and a solid central body. They can be rapidly installed thanks to their two sharp ends, which function like saw blades to penetrate the material. As the rivet cuts through, the split ends bend back to create a secure and tight connection.
Heavy duty staples, essential in road case manufacturing, are designed to firmly secure fabrics and panels. Available in various sizes and lengths, they are used to fasten fabric, corners, and edging materials effectively, similar to rivets.
The performance and stability of a road case is enhanced by the types of metals used to protect its corners. The typical metals are single angle or double angle aluminum extrusions.
Single angle aluminum is lightweight yet strong and durable. Available in thicknesses ranging from 0.17 inches to 0.25 inches, these extrusions are used in diverse applications, including truck beds and decorative purposes. Typically made from the 6063 alloy, which includes magnesium and silicon, single angle aluminum corners provide substantial strength.
Double angle extrusions feature two channels, allowing the wood sides of a road case to slide in and be supported on both the inner and outer walls. Unlike single angle extrusions, double angle extrusions provide a more secure corner fit, enhancing the overall strength.
Edges are fitted around the openings of a road case to maintain a secure closure when the lid is shut. They ensure that the lid and base align perfectly and remain tightly sealed. Edges are crucial for all road cases with openings, regardless of whether the lid and base are separable.
A tongue groove edge uses a groove extrusion paired with a tongue extrusion to create a secure seal between the lid and base of a road case. These extruded channels are designed to fit over the case's edges, with one channel featuring a groove and the other a rounded tongue.
Hybrid extrusions combine features of tongue and groove designs but utilize the same extruded channel pieces for both the lid and base. Each piece fits over the edges of the lid and base, interlocking to ensure a tight and secure closure.
The slam shut edge consists of a straightforward U-shaped aluminum channel that covers the edge of the lid and base. Unlike tongue and groove designs, it lacks any interlocking features. This type of edge serves to protect the edges of the road case from damage but does not create a tight seal, making it the most economical option.
Metal right angle strips are used to safeguard the corners and edges of a road case where the sides converge. At the top and bottom of these strips, ball and flat corners are added to offer additional protection to the case's corners.
Panels for fabricated road cases are typically constructed from either plain or pre-laminated plywood, with pre-laminated being the more prevalent choice. Plain plywood is often treated with paint or polyurethane coating, with the coated version generally being more durable compared to the painted type.
Birch plywood, commonly used in road case construction, has a thickness of 9.5 mm or 0.375 inch. It is favored for its lighter weight, durability, resilience, and ability to resist dings, dents, scratches, and moisture. For heavy-duty applications, thicker coated plywood is preferred to endure the stresses of shipping and handling.
Thermoplastic laminate is applied to the sides of road cases by gluing it onto the plywood and then passing it through pressure rollers to ensure a consistent and strong bond. To further ensure durability, the laminated plywood is often subjected to a heat press to cure the adhesive.
Piano hinges are normally used in the construction of road cases since they are long continuous hinges with multiple holes for the placement of rivets. Hinges for road cases are made of heavy duty steel, which makes them capable of withstanding constant stress.
Torque hinges, also known as free stop hinges, are installed at intervals of four to six inches and function as lid stays to keep the lid of a road case open while preventing it from closing. These hinges are typically crafted from aluminum or steel and are available in various sizes to accommodate different case designs.
Handles on road cases are usually recessed into the sides of the case. During the fabrication process, holes are cut into the laminated plywood to accommodate these recessed handles, which are then riveted into position. The recessed design allows for easy stacking of road cases and simplifies lifting them.
Various types of lid stays are available depending on the size and design of the road case. For smaller road cases, nylon web stays are suitable as they can manage and support lighter lids. In contrast, larger and more heavy-duty road cases require steel recessed lid stays, which offer greater strength and durability for handling heavier lids.
The rotomolding process is a method for producing large single piece road cases from polyethylene powder and includes placing the powder in a mold that is heated and rotated to evenly distribute the powder. Road cases made by rotomolding are considered to be more durable due to the increased concentration of plastic in the corners and its uniform density. It is a four stage process that includes loading the plastic resin, rotating and heating the mold, cooling the mold, and removing the molded case.
Various polymer resins are employed in the rotomolding process, with different types of polyethylene being among the most frequently used. In this process, polyethylene is ground into a fine powder, measured for accuracy, and then placed into the mold cavity for shaping.
After loading the resin material, the mold halves are fastened and sealed using bolts or clamps to ensure they are tightly secured.
The rotary mold mechanism includes the mold itself and a mechanical arm capable of rotating the mold along multiple axes. Once engaged, the mold is positioned in a heating chamber where it is heated to melt the resin. This melted resin gradually and evenly coats the interior of the mold, filling all the intricate facets of the cavity.
Monitoring the heating process is crucial. Overheating can lead to the degradation of the polymer resin, resulting in a weaker road case, while insufficient heating may cause the final product to be misshapen or deformed.
The cooling phase generally lasts around 20 minutes or longer. During this time, the molded road case gradually shrinks as it releases from the mold's sides. This slow process helps prevent warping or cracking. The cooling involves using fans to blow cool air and a fine mist of water to reduce the temperature. The molded piece cools below the crystallization point and undergoes partial curing.
After the road case has fully molded, it is taken out of the mold and undergoes trimming, cutting, and shaping to accommodate hinges, latches, lid stays, and edge U channels. Because rotomolding creates a single solid piece, there is no need for aluminum angles at the corners or additional knuckles and flat corners. This method results in a robust and durable road case, well-suited to handle rough handling and abuse.
In the injection molding technique, plastic resin is melted and then forced into the mold. Similar to rotomolding, the mold for injection molding is made of two halves that are sealed together before the molten thermosetting plastic pellets are injected. The process begins with creating a precise steel or aluminum mold, tailored to the exact specifications of the road case.
Injection molding utilizes two main types of plastics: thermosetting and thermoplastic. For road case manufacturing, thermosetting plastic is preferred. Once it has been cured, thermosetting plastic cannot be melted or reused.
Unlike rotomolding, which involves rotating the mold, injection molding relies on applying pressure. The mold's two halves are tightly clamped together to endure the high pressure involved in the process.
The initial stage of injection molding involves heating the resin pellets. This begins with feeding the pellets into the heating barrel via a hopper. Gravity hoppers, positioned above the start of the barrel, are the most commonly used type for this purpose.
The resin pellets enter the barrel, where a rotating helical screw pushes them toward the mold. Heaters positioned along the barrel melt the pellets as they advance. The melted resin is then injected into the mold with force and speed, similar to the rotary molding process, spreading it evenly across the mold’s surface.
Pressure is used to expel any air trapped in the melted resin through vents and parting lines incorporated into the mold design.
Similar to rotomolding, the heated resin must cool within the mold, with cooling times depending on the type and consistency of the plastic used. To ensure uniform cooling, water is circulated over the mold. Meanwhile, the screw retracts to prepare for the next injection cycle.
After the molding process, the mold is opened to extract the finished road case. Any excess material, known as runners, which may have collected on the mold edges, needs to be removed. This cleanup is typically performed mechanically or with robotic assistance as part of the final finishing process.
Injection-molded road cases are manufactured as a single, solid piece of durable plastic, eliminating the need for metal edges or corner reinforcements like flat or ball corners. While aluminum edges, metal hinges, latches, and handles may be added to the lid and base, the uniformity of the molded case means that rivets are not needed to join the sides.
All road cases serve the same primary function of safeguarding and securing sensitive equipment, but they can be customized with various accessories to meet specific transport or protection needs. Manufacturers offer a range of add-ons to tailor road cases to their intended use.
Different types of casters are utilized in road case design, depending on the size of the case and the weight of its contents. Casters are essential for facilitating the movement and handling of road cases.
Spinner casters allow for 360° rotation, enabling easy movement of a road case in any direction. Available in various sizes and designs, spinner casters are attached with either metal flat brackets or corner brackets.
In-line casters are designed to move in a single direction and can be recessed into the road case for a streamlined profile.
Locking mechanisms on casters, typically found on spinner casters, enable the road case to remain stationary while in use, providing stability for accessing the case's contents.
Retractable handles are available for smaller road cases such as sample cases, trade show cases, and design cases. Road cases with retractable handles come with one or two sets of casters depending on the size of the case and are easily maneuvered using the handle.
In some road case designs, foam inserts are essential for safeguarding the contents. These inserts help secure and cushion the items during both transport and storage, reducing the risk of shock or damage. For specialized applications such as military gear or medical tools, the foam is carefully cut and customized to provide optimal protection.
The three primary types of foam commonly used for inserts include:
Apart from being used to create inserts, foam is also fitted into the lids of road cases, offering extra cushioning and safeguarding the contents.
Road cases offer an excellent solution for transporting sensitive technical equipment and delicate devices. They ensure that the gear is securely protected, providing peace of mind that the equipment will reach its destination intact and operational. When choosing a road case, it's crucial to consider key factors to ensure the right selection for the shipping needs. Many manufacturers offer convenient online tools to help guide the selection and design process.
Standard road cases are versatile and can be used in various conditions. These cases are typically shaped like trunks and may come with or without padding, depending on the specific design. As general-purpose utility cases, they can accommodate a wide range of devices. However, they lack customized foam inserts or drawers and are designed for general use, fitting most items.
When choosing a standard road case, it's important to select one that matches the intended use. Careful consideration will help prevent the mistake of choosing a case that is too large or too small for the equipment. Measuring the items that will be stored in the case is the best way to avoid this issue.
Unlike general-purpose road cases, custom-designed road cases require precise and accurate measurements. Manufacturers often provide online dimensions to simplify the selection process for customers. These measurements serve as a starting point and reference for choosing the right case.
To ensure a perfect fit for an instrument, it's necessary to measure its maximum length, width, and height, so it fits well within the rectangular shape of a road case. Additionally, customers can submit images, CAD drawings, or sketches of the items to be transported, enabling manufacturers to cut and shape foam inserts accordingly.
Since many devices come with additional components such as power buttons, decks, switches, and controllers, it’s essential to include their dimensions in the measurement process. By doing so, the road case can be designed to accommodate all aspects of the equipment, ensuring comprehensive protection.
All road cases are crafted from materials engineered to withstand rigorous and demanding conditions. This durability is a key reason for their widespread use. Manufacturers understand the challenging environments these cases may encounter and incorporate these considerations into the design process.
To guarantee a case’s durability, the materials chosen are tailored to the expected usage. Light-duty cases are intended for storage and occasional use, while heavy-duty cases, which meet A4A standards, are built for frequent use and transporting heavy items. The intended use of the case determines the choice of materials for the exterior and the type of interior foam protection.
Reputable road case manufacturers ensure that their products meet A4A certification standards. While A4A certification is the highest standard, cases are also certified by other agencies for dust, water, and impact resistance. Additionally, Military Standard 810G certification indicates that a road case is suitable for military use.
Certified road case manufacturers can produce cases that meet the stringent standards and requirements set by the United States government, the Airlines for America Association, and the Department of Transportation (DOT).
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