Equipment Hard Case Guide | 5 Most Common Types

What Makes a Great Equipment Hard Case?

Choosing the right equipment hard case isn’t just about picking a container. It’s about protecting your tools, technology, and brand reputation. From military deployments to medical missions, sales demos to field diagnostics, the right case ensures your equipment arrives safely and functions flawlessly.

At CH Ellis, we offer a full range of case types—each with distinct advantages. This guide will walk you through the most common options, their key features, and what types of projects they’re best suited for.

Hard Case Type Comparison Chart

Case Type	Durability	Waterproof?	Weight	Best For
Rotomolded	⭐⭐⭐⭐⭐	✅	Medium	Shipping, military, rugged use
Vacuum Formed	⭐⭐⭐⭐	❌	Light	Toolkits, trays, hybrid interiors
Injection Molded	⭐⭐⭐⭐	✅	Light-Med	Tech, med kits, IP-rated protection
Aluminum	⭐⭐⭐⭐	❌	Light	High-value tools, RF protection, demos
Blow Molded	⭐⭐⭐	❌	Light	Budget-conscious storage, product kits, tools

Best For: Shipping, military gear, heavy equipment, outdoor field use

Recommended Brands: Parker Roto-Rugged™, Pelican-Hardigg™, Gemstar

When it comes to durability, rotomolded cases are in a class of their own. These cases are made by heating plastic resin in a rotating mold. This process creates seamless walls with thick corners, which help absorb shock and resist impact. Our Parker Roto-Rugged™ cases are a prime example—built for performance, priced for value.

Why Choose Rotomolded?

✔ Extreme Impact Resistance – LLDPE material handles drops, bumps, and brute force with ease
✔ Ideal for Shipping – Perfect for air freight, military deployment, or field service
✔ Endless Customization – Hardware, branding, foam interiors, and even double-walled designs
✔ Lower Tooling Cost than Injection Molding – Great for moderate production runs
✔ Custom Colors – Achievable with low minimum order quantities
✔ Stackable Designs – Save space in storage and transport

Applications:

• Military and tactical equipment
• Rugged field instruments
• Large toolkits
• Rack-mounted electronics
• Heavy shipping use
  

CH Ellis also offers stock and custom Gemstar Stronghold™, RoboRack™, and Pelican-Hardigg™ rotomolded cases to match mil-spec standards or unique shipping needs.

Best For: Toolkits, modular foam interiors, hybrid pallets, custom trays

Recommended Brand: Chicago Case™

Vacuum formed cases strike a smart balance between durability and weight. Using vacuum pressure and heat, we mold HDPE or ABS sheets into durable, lightweight cases. Our Chicago Case™ line includes over 100 molds, helping us offer custom-fit solutions—often with no tooling cost.

Why Choose Vacuum Formed?

✔ Lightweight Efficiency – Lighter and more compact than injection molded cases
✔ Cost-Effective Customization – Fast and affordable tooling, even for unique sizes
✔ Versatile Interiors – Use foam, pallets, or both for organized protection
✔ Durable and Chemical Resistant – Handles tough use in cleanrooms, job sites, and beyond
✔ Speedy Production – Perfect for mid-volume runs and fast turnarounds

Applications:

• Custom toolkits with organizing pallets
• Sales/demo kits
• Shipping with internal organization
• Trays and housings for electronics or instruments
• Device cases with deep-draw geometry
  

All CH Ellis vacuum formed cases are molded in-house in Indiana using state-of-the-art equipment like our Maac Comet shuttle machine and Koehring Brown rotary thermoformer.

Best For: Electronics, medical gear, military and law enforcement kits

Recommended Brand: Pelican™, Nanuk™, Gemstar Sentinel™, Maxado™

Injection molded cases are the go-to when water resistance, precise sizing, and stackability matter most. Though CH Ellis doesn’t mold these in-house, we proudly distribute and customize Pelican™, Nanuk™, Gemstar Sentinel™, Maxado™, and other top brands.

Why Choose Injection Molded?

✔ Watertight and Airtight – Many carry IP67+ ratings and mil-spec compliance
✔ Precision Fit – Ideal for sensitive electronics and gear that must stay protected
✔ Professional Appearance – Sleek, clean lines suitable for field or boardroom
✔ Extensive Customization – Custom foam, hardware, branding, and more

Applications:

• Law enforcement or tactical cases
• Sensor and drone storage
• High-end electronic presentation kits
• Medical diagnostic equipment
• Instrument protection
  

We specialize in customizing these premium cases with CNC foam, integrated components, pockets, pouches, and full brand treatment. Our relationship with Pelican gives us a logistical edge on pricing and delivery.

Best For: Tool storage, basic protection, commercial kits, sales samples

Blow-molded cases offer a lightweight, cost-effective option for storing and transporting equipment that doesn’t need heavy-duty protection. These cases are made by blowing heated plastic into a mold. This creates a double-walled structure that is strong and shock-resistant.

While not waterproof, blow molded cases are a solid choice for light- to mid-duty applications where affordability and volume matter. CH Ellis offers a wide selection of standard and custom blow molded cases in a variety of sizes and configurations, ideal for tool sets, product kits, and parts storage.

Why Choose Blow Molded?

✔ Lightweight & Impact-Resistant – Great for handheld kits or frequent transport
✔ Budget-Friendly – One of the most economical hard case options available
✔ Foam & Insert Options – Support basic customization
✔ Ideal for Volume Projects – Commonly used in retail or distribution

Applications:

• Power tool kits
• Diagnostic sets
• Sales sample kits
• Instructional tools or repair kits
• Product packaging requiring presentation and protection
  

Need a case that looks good, protects well, and won’t break the bank? Blow molded cases strike that balance beautifully.

Best For: High-value tools, heat-sensitive gear, executive demos, rack-mounted electronics

When image and integrity are equally important, nothing beats a CH Ellis aluminum case. TIG-welded and rigidized with a classic diamond pattern, our aluminum cases offer a professional look backed by serious protection. Whether you’re presenting a product or traveling with precision tools, these cases protect what matters—with style.

Why Choose Aluminum?

✔ Lightweight Strength – Stronger than plastic and resistant to deformation
✔ Heat Protection – Naturally dissipates heat
✔ Corrosion Resistant – Ideal for moisture, UV, and chemical exposure
✔ Maximum Security – Integrated lock options for peace of mind
✔ Sleek, Premium Appearance – A professional finish that elevates your brand
✔ Low-Volume Friendly – Great for custom runs or specialty applications

Applications:

• Medical and diagnostic devices
• Circuit boards and electronics
• Professional toolkits
• Photography and media gear
• Oil rig or remote field equipment
• Rack-mounted systems
• Sales and demo kits
  

Available with custom foam inserts, branding, specialty latches, compartments, and more—these cases are the perfect union of form and function.

Need Help Deciding? Let’s Talk.

Choosing the right case depends on what you’re protecting, where it’s going, and how it needs to perform. At CH Ellis, we don’t just supply custom equipment hard cases—we design solutions. Give us a call if you’ve got questions, or share your project by filling out our case RFQ form.

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