Case selection is the first step in the custom foam panel design process. Only NANUK cases can be fitted with a custom panel. Many NANUK cases offer both lid and base mounting options. Check our case products pages to find the case with the right configuration for your application. Once the case is chosen the final step in the selection process is to decide on a case color.

To begin the design process we require drawings in either 2D or 3D format that accurately represent the shape and size of the panel cut-outs. If text is required on the panel this should also be specified.

Plasticase offers different types of materials for your panel project. The three material types that are commonly specified is aluminum, polycarbonate or Alupanel which is a polyethylene aluminum composite. Material selection is usually dictated by 3 factors: engineering requirements, aesthetic appeal and price.

Once we have all the technical information required to proceed with the design process our team of designers will prepare a set of drawings that clearly illustrates your panel layout along with fit in the case. These drawings will also indicate all engineering details required to manufacture the panel. Your representative will send you the drawings for preliminary approval to proceed to the prototype phase.

Once the drawings have been reviewed and accepted by the customer we will produce a prototype to confirm fit and function of the design. Our engineering department will review the prototype to confirm the foam meets the initial requirements. Once the prototype has passed our internal QC procedure we will ship the foam inside the case for customer review and approval.

Your sales representative will arrange to have the prototype shipped to you for review and approval. If the prototype is to your satisfaction simply sign the provide production approval drawings and we are ready to start production. Occasionally it may take several revisions and/or prototypes to get the fit just right.

Once the panel design is approved we can move into production. There are two different methods we use to manufacture the panel depending on the requirements of the project and the material type. CNC router or laser cutting will be used to produce the perfect panel for your project.

The panel production process is constantly monitored to ensure a consistent quality throughout the production cycle. Important elements checked during the QC process include material quality and cut-out profiles keeping a close eye on the required tolerances. Our strict document control process ensures that all specifications unique to your project are clearly indicated to ensure each production meets your expectations

Whether you need 10 cases or 10,000 cases Plasticase has the expertise to deliver a complete case solution on time and on budget.