Case Studies

Case Studies

Tetrafab offers a variety of materials, professional design, and several logo options for all of your custom-sewn soft case needs. From durable nylon to flexible neoprene, we have the materials you need to create the perfect custom case solution. Click on the boxes below to see our case studies, and see how we have helped major companies design and produce innovative case solutions for their unique products.

CLIENT:
Network Solutions Firm

SHORT DESCRIPTION:
The client needed a functional case to house their sensitive network testing tablet. They wanted a backpack that employees could use in the field that would transport and protect all the accessories and cables needed for network testing.

SPECS:
Thermoformed foam EVA backpack with 2 compartments, mesh pockets, hidden zipper pull, and padded pockets.

EVA backpack

CHALLENGE:
An enterprise network solutions firm contacted us with a need for an EVA hard-shell backpack to house an advanced network testing tablet and some cable accessories. The tablet itself was quite large, and had some large rubber handles built-in to either side of the screen. The main challenge here was to create a protective case that wasn’t too bulky, but also sturdy enough to stand up to a tough working environment without damaging the sensitive equipment. We also had to integrate multiple pouches and zipped compartments to house the cables, meters, and attachments for the tablet. Lastly, they wanted the backpack to be ergonomically beneficial and have plenty of padding so that the end user could wear the pack during an entire 8 hour work day and not be uncomfortable or perspire excessively.

SOLUTION:
Our design team created a cad file to pinpoint the exact dimensions of the tablet. Once completed, we designed a special EVA tool for the hard shell facing away from the back of the wearer. The pack itself had 2 main compartments: The outermost compartment contained the formed foam EVA shell, which houses the tablet device, as well as some components for testing. The zipper pull is hidden in a seam, giving the case a more streamlined look. Inside the front compartment is also a mesh pocket, and multiple sleeves for various cables and accessories. The back compartment contains mesh pockets and a padded sleeve for a laptop or the tablet if the other pocket is full. The back of the backpack is equipped with a mesh foam padding to allow breathability and the straps clip together to distribute the weight on the hips instead of only on the shoulders.

RESULTS:

The case was a success and workers in the field absolutely loved the comfort and storage capabilities the backpack provided. The hard shell EVA gave them peace of mind when traveling from jobsite to jobsite because they didn’t need to worry about damaging their instruments in transit. We were able to design a custom backpack that was not only aesthetically pleasing, but also highly functional and provided our client’s employees with a field-ready backpack that made them more efficient and protected their sensitive equipment.

CLIENT:
Quadcopter Manufacturer

SHORT DESCRIPTION:
The client had a very unique challenge for us: create a highly stylized case that would be able to protect their state-of-the-art drone. Our design team hit a home run.

SPECS:
Thermal formed foam EVA case with branded zipper pull, velcro hand strap.

CHALLENGE:
We were approached by a private group who had an incredibly ambitious vision for a state-of-the-art drone. Their concept had just made a big splash at CES 2015 and was coming off of the one of the most successful Kickstarter campaigns of all time. Our client was extremely excited about their new product, but wanted to make sure they gave their investors a complete package when it was time to start shipping orders. The main challenge for the case was getting the design and aesthetic aspects of the case right, while also making sure the case was sturdy and able to adequately protect the delicate quadcopter. Due to the specs of the drone itself, the case needed to be form-fitting and extremely precise. They also needed to have extra space to store the backup battery, as well as some straps inside the case for extra security.

SOLUTION:
Our design team was able meet our client’s demands, and even added some extra styling and functionality to their original design concept. The EVA foam shell was wrapped in 3 different polyester overlays: bright red, black, and a traditional pixelated camo pattern. These different color profiles really made the case pop and gave their customers a few different styles to fit their customer’s specific tastes. We had the company logo stitched to the front of the case, and added some contour to the EVA mold for some truly unique style. For the bright red case, we used a brushed nickel on the center button that showcased a birds-eye view of the quadcopter, and doubled as their signature logo. The black zipper pull gave the case a nice accent, and we branded the rubber pulls with red lettering for branding. The inside of the case featured the logo and company name molded onto the shell, with four Velcro straps to secure the drone while transporting. We also added a mesh pocket to the top half of the case to store a backup battery pack for longer flight times.

RESULTS:
The case was a huge success, and both our client and their customers were elated with the overall look and feel of the finished product. The different color options added a level of customization and personality that perfectly aligned with their diverse customer base. Here at Tetrafab we love gadgets and innovative technology, and we thoroughly enjoyed getting the opportunity to create what we feel is one of our most exciting projects to date.

CLIENT:
Dunn Edwards

SHORT DESCRIPTION:
Our design team worked tirelessly with the client to create a 100% custom case with elevated style and branding. The case was a hit and the client was elated with Tetrafab’s custom case solution.

SPECS:
Thermal formed foam EVA case with carbon fiber PU overlay, custom heat transferred logo.

Eva case

CHALLENGE:
Recently, a client came to us with a very unique challenge: create a case that was as aesthetically pleasing as it was functional and convenient. Because the end user would be using this case as a marketing tool, the look and feel of the case was extremely important. The major challenge here was to make something that was visually appealing and easily accessible, and to create a design that would really show off the color variations that people look for when choosing paints. Interior designers would be using our case to house a catalog of color palettes to show their clients. Accessibility was a major concern because the designers would need to easily swap color swatches in and out of the case pockets.

SOLUTION:
By working closely with our client throughout every step of the design process, we were able to turn their initial concept into a reality. We ended up going with a thermal formed foam EVA case for the shell, in order to protect the color palettes. To add some texture, we overlaid the Eva foam with a carbon fiber PU, and then created some deep ridges to the front and back of the case for style. The orange stitch accent to the shoulder strap and handles, along with a matte orange zipper, created some recognizable branding to match the orange in the client’s logo. The heat transferred rainbow polygons on the front of the case really added some pop to the overall look, and we decided to use the same technique for the front logo and Perfect Palette© text. On the inside of the case, we created staggered foam pockets for the palettes, and added a fold out sleeve, textured with same carbon fiber PU overlay used on the shell to hold the booklet, business card, and a few extra pockets for documents. Elastic bands hold the piece of formed foam down for easy access to the color palettes, and the company name was stitched onto the top piece for more brand recognition.

RESULTS:
Throughout several design phases, we were able to create a case that not only met our client’s requirements, but exceeded them. The case was truly one of our best creations to date. The resulting product was a functional case that will help the end user market their incredible products to prospective clients, all while maintaining clear brand recognition and undeniable style.

CLIENT:
Electronics Manufacturer

SHORT DESCRIPTION:
A major electronics company needed a custom case to house their maintenance meter, along with a utility EVA case that the meter case could attach to that would hold testing cables, plugs, and other accessories.

SPECS:
2 EVA cases with polyester overlay, heavy duty zipper pull, mesh pocket interior with velcro compartments.

EVA case

CHALLENGE:
The main challenge with this project was making two separate cases that could function as one. Our client wanted the front piece that housed the actual meter to be easily detachable, yet firmly secure to the case. The accessory case needed to be heavy duty, have a branded style, and be able to withstand an unforgiving work environment. Because the accessory case also needed to be able to store and organize a plethora of cords, cables, and attachments, we had to get very creative with the design of the interior in order to maximize storage space.

SOLUTION:
For the meter case, we went with an EVA foam shell wrapped in black polyester, with the logo and part name stitched onto the front. The flap on the front that covers the screen of the instrument secures to the base via magnetic strips on either side. The side of the case features a velcro adjustable hand strap for secure and easy transport. In order to attach to the accessory case, the back of the meter case has a velcro flap that threads through a strap on the front of the accessory case, along with two metal rings on the top corners for the clasps on the accessory case to hook onto. The accessory case is also an EVA shell wrapped in polyester, and features red accent straps for the front clasp and handles, as well as a rubber logo for some added aesthetic quality and branding. The case zips open with a heavy duty extra large zipper pull, and two interlocking rings that allow for a padlock to secure the case. The piece opens up and showcases two folder pockets on each half, secured with a velcro strap to keep the contents secured. The folder flaps each have velcro pockets, as well as multiple zipper mesh compartments. The flaps open up to reveal more mesh pockets on the back, and the interior of the case sports deep mesh pockets with velcro harnesses to house larger tools and equipment. Finally, the bottom of the case is fitted with 4 pegs that enable the case to stand firmly upright.

RESULTS:
The client was extremely pleased with the final result. The project exceeded their expectations, and increased the value of their products, all while providing the end user with the best possible experience while on a job site.

CLIENT:
Tactical Scope Manufacturer

SHORT DESCRIPTION:
Our client required a 100% custom sleeve to house a high-powered scope, along with a custom carrying case to protect the scope and the other components needed for tactical operations.

SPECS:
Formed Foam EVA case with custom foam inserts, custom polyester sleeve with rubber logo and zippers.

EVA case

CHALLENGE:
The main challenge for this project was manufacturing an extremely complex, but precisely fitted sleeve for the scope on a large scale with little to no defects. After that, we needed to tool a custom EVA case with compartments to hold the scope with it’s custom sleeve, along with all the available accessories.

SOLUTION:
By working closely with our client’s team, we were able to meet, and even exceed, the requirements for this delicate equipment. The sleeve that houses the scope is actually an EVA shell that is wrapped in a durable polyester. This sleeve has a total of 4 buttons, 3 separate zipper pulls, and a buckle that allow you to detach parts of the case individually. This allows the user to access different parts of the scope for cleaning and calibration purposes. The rubber logo on the front, as well as the custom logos on the zipper pulls, adds some truly unique aesthetic properties. The EVA case has a large central compartment for the scope and sleeve, and two extra compartments for the scope’s accessories. The back panel has a velcro shelf that is removeable and can store a spare shoulder strap, or whatever else the user may want to carry. The zipper pulls on the case are heavy duty, and can withstand the elements and large amounts of stress that often occur when used in the field. Rings were added to the sides of the case that allow users to attach a comfortable shoulder strap for long distance carrying.

RESULTS:
The case was a total success, and the client was amazed by the quality of the final products. By tooling a custom mold specifically for the project, we were able to mass produce this complex design with the same rigorous quality standards we demand for every case we manufacture.

CLIENT:
Leading Healthcare OEM

SHORT DESCRIPTION:
Our client required a way to carry an lifesaving AED device with all the necessary attachments, so they came to Tetrafab.

SPECS:
Thermal Formed Foam EVA shell with lycra interior, plastic feet on back, clear PVC business card holder, large custom rubber logo on front.

EVA case

CHALLENGE:
The client needed an all-in-one case for medical professionals and untrained civilians to be able to transport their life-saving AED device in an emergency situation. The AED (automatic external defibrillator) requires several extra tools to function properly, including a razor, the self-adhesive pads, spare electrodes, and the connection wires. They needed a case that would house these components but be easily accessible for quick response times in a life-saving situation.

SOLUTION:
Our design team worked very closely with their engineers to create an optimal case design that would be rigid enough to easily transport, but also be easily accessible and user-friendly. The semi-rigid design allowed the case to stand upright on its own, or be able to open like a briefcase when laid on its back. Additionally, four plastic feet were added to the back of the case to prevent the case from sliding around when laid down. A separate compartment was added to house the spare electrodes, which is clearly labeled with a rubber stamp that sticks out of the top of the zipper. Their custom rubber logo was put on the front of the case with a window in the center that aligns with the design on the AED itself.

RESULTS:
The case was a home run and they continue to be one of our most valued customers. Several different variations of the case have been made over the years to fit different and newer models, including a wall-mounted version that can be found in schools across New Jersey. Their AEDs have saved hundreds of lives across the U.S. and Tetrafab is honored to have the privilege of helping to design and create a case for such a unique product, which has positively impacted so many people’s lives.

CLIENT:
KFC

SHORT DESCRIPTION:
YUM! brands fast food giant KFC needed a large catering bag to keep their orders warm and organized during a delivery.

SPECS:
Thermal lining interior, polyester exterior with detachable shoulder strap, clear PVC screen, velcro handles, and two velcro side pouches for storage.

Soft Case

CHALLENGE:
Yum Brands giant KFC needed a stylish, branded catering bag for their delivery services. The bag needed to be large, have a number of different pockets and compartments, and a clear PVC screen to easily see and remove tickets, receipts, and credit card slips.

SOLUTION:
We went with a bright red polyester material to cover the bag, with a foam insert in the bottom of the case for a rigid form. The two side pockets on each side are velcro for easy access, as is the main flap on the top of the bag. The handles also velcro together to prevent the bag from accidentally opening. A removeable shoulder strap for long distance carrying or heavy loads added some customizable functionality to the product. Stitched logos on the sides, front and back of the case added style and branding that really makes the bag pop. Finally, the steam vent holes on the bag prevent food from getting soggy, allowing the orders to be delivered hot and fresh, even when traveling long distances to their destination.

RESULTS:
The bag was a hit and is currently being used in KFC restaurants across the U.S.

CLIENT:
Intel Health

SHORT DESCRIPTION:
Fortune 100 Digital Healthcare company Intel Health was able to increase their product’s functionality, protection, and flexibility while magnifying their brand marketing efforts using Tetrafab custom case solutions.

SPECS:
EVA shell 600D polyester case with lycra interior, custom molded rubber logo on front and custom rubber zipper pull with logo.

neoprene computer case

CHALLENGE:
Tetrafab was approached by Intel Health, a manufacturer of a mobile device for people with reading based learning disabilities such as dyslexia and blindness, with a unique idea. They assigned the project to a design house to deliver a case that provided protection, access and functionality to this ultra-mobile pc. This project initially looked impossible due to the large number of openings required on the case, making it unfeasible to produce using normal manufacturing processes. Their Marketing department also desired something small and aesthetically pleasing that displays their corporate logo in multiple ways.

SOLUTION:
In keeping with the desired vision, our team designed a custom thermo-formed case manufactured with new technically advanced equipment to achieve their goals. This allowed us to meet very strict tolerances while giving the finished product an aesthetically cleaner look. We also conceived a strategy for utilizing a combination of a living hinge and magnets and self-centering lid for ease of use by people with vision impairments. A sample was then manufactured to show the quality and attention to detail that Tetrafab is known for in the industry. To help their marketing efforts, we were able to include an embossed company logo on the bottom of the case. Tetrafab also initiated using both a custom zipper pull and molded rubber trademark on the front and top of the case respectively.

RESULTS:
The custom formed foam case designed by Tetrafab was able to provide the required protection and accessibility functions. By thinking outside the box, Tetrafab was able to develop equipment and expertise for laser cutting that solved the design and manufacturing issues inherent with the case. The end-user was able to easily use all of the features of the ultra mobile PC while it was still effectively encased. It allowed them to enhance their independence, as it gave them more flexibility and freedom by reading the printed material aloud. The customer was also able to more effectively market their brand through the use of the three unique marketing applications. By working with Tetrafab, they were able to dramatically improve their product line’s overall effectiveness.

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**NOTE** WE ONLY ACCEPT BULK ORDERS. OUR TYPICAL MOQ IS 500+ PCS.