Custom Vacuum-Formed Cases
Lightweight Protection. Built Around Your Application.
Trusted by dozens of Fortune 500 corporations, and the U.S. Military
Why Choose a Vacuum-Formed Case?
Vacuum-formed cases offer a versatile middle ground between lightweight portability and industrial-strength protection.
C.H. Ellis manufactures custom vacuum-formed cases that combine durable protection, efficient use of space, and extensive customization without the weight of heavier hard case designs.
Lightweight & Space-Efficient
Thin, durable walls help reduce overall case weight and exterior dimensions compared with many heavier hard case options.
Cost-Effective Customization
With 100+ existing molds and flexible depths, vacuum forming accommodates many applications without new tooling.
Built for Industrial Use
HDPE and ABS material options provide impact and chemical resistance for demanding environments.
Interior Flexibility
Pair your case with custom foam, tool pallets, thermoformed trays, or hybrid interior systems.
How Vacuum Forming Works
Vacuum forming begins by heating a plastic sheet until it becomes pliable. Vacuum pressure then draws the material over or into a mold, creating the shape of the case.
C.H. Ellis performs this process in-house in Indiana using two thermoforming systems, giving us greater control over design, manufacturing consistency, and production schedules.
Maac Comet Shuttle Machine
Provides precise control for complex shapes, deeper draws, and demanding custom designs.
Koehring Brown Rotary Thermoformer
Provides efficient production for less complex, repeatable applications.
Vacuum-Formed Case Materials
High-Density Polyethylene (HDPE)
HDPE provides rugged impact and chemical resistance similar to the material used in truck bed liners. It is well suited for industrial tools, field equipment, and frequently handled cases.
Acrylonitrile Butadiene Styrene (ABS)
ABS provides durable protection with a more refined appearance, making it a strong choice for presentation, technical, and customer-facing applications.
Chicago Case™ by C.H. Ellis
Our Chicago Case line combines decades of case manufacturing experience with more than 100 available vacuum forming molds.
Choosing an existing mold can help reduce tooling requirements while still allowing extensive customization around your equipment and workflow.
Available features
- Gasketed, interlocking aluminum valances
- Military-style butterfly or metal briefcase latches
- Spring-loaded and briefcase-style handles
- Field-replaceable telescoping handles
- Heavy-duty, field-replaceable wheels
- Custom colors and hardware options
- Molded corner protection on select configurations
Build the Interior Around Your Equipment
The versatility of vacuum forming continues inside the case. Depending on your application, C.H. Ellis can engineer a complete interior system using:
Custom Foam Inserts
Precision-cut protection for instruments, electronics, tools, and sensitive equipment.
Tool Pallets & Organizers
Sewn and structured layouts that improve tool access, visibility, and accountability.
Thermoformed Tray Inserts
Defined, easy-to-clean compartments for tools, components, hardware, and kits.
Hybrid Systems
Combine foam, pallets, and trays when different areas of the case require different types of protection or organization.
Vacuum-Formed Case Applications
Tool Kits & Field Service Equipment
Lightweight cases with organized interiors help technicians transport and access tools efficiently.
Test Equipment & Instrumentation
Custom foam and tray systems provide structured protection for gauges, test instruments, and technical equipment.
Medical & Technical Equipment
Durable, professional cases support equipment that requires organized transport and frequent access.
Sales & Demonstration Kits
ABS cases and custom interiors create polished, organized presentations for products and samples.
Shipping & Protective Packaging
Vacuum-formed cases provide durable, reusable protection when IP-rated water intrusion protection is not required.
Need a Fully Custom Vacuum-Formed Case?
When an existing mold does not match your requirements, C.H. Ellis can develop custom tooling around your product.
Vacuum forming offers a cost-effective and adaptable approach to custom case production. Tooling costs are typically lower than injection molding, while a single mold can accommodate multiple case depths. Textures and colors can also be changed with minimal tooling impact, providing added flexibility as product or branding requirements evolve.
Our engineering team can help determine case dimensions, material, hardware, interior configuration, and exterior features. Customers can own their tooling, with options available to amortize tooling expenses across production.
This flexibility makes custom vacuum forming particularly well suited to repeat B2B programs that require a purpose-built case with manageable tooling investment.
Find the Right Vacuum-Formed Case
Tell us what you’re protecting, how it’s used, and where it’s going. Our in-house design and manufacturing team will help determine whether an existing Chicago Case mold or a fully custom vacuum-formed case is the right fit.
Vacuum-Formed Case FAQs
What is a vacuum-formed case?
A vacuum-formed case is manufactured by heating plastic sheet material and drawing it over or into a mold using vacuum pressure. The process produces lightweight, durable hard cases with significant design flexibility.
What materials are used for vacuum forming cases?
C.H. Ellis primarily uses HDPE for rugged industrial applications and ABS when a more refined appearance is desired.
Are vacuum-formed cases waterproof?
Vacuum-formed cases are not submersible, but they are generally splash and spray resistant. With the right configuration, a vacuum-formed case can achieve approximately IP65 protection, meaning it is protected against low-pressure water jets from any direction, such as rain or hosing down. Applications requiring immersion protection, such as IP67, may be better served by an injection molded case.
Can you manufacture a completely custom size?
Yes. C.H. Ellis can create custom tooling when an existing mold does not fit the application.
Can vacuum-formed cases have custom interiors?
Yes. Interiors can incorporate custom foam inserts, tool pallets, thermoformed trays, sewn organizers, or hybrid systems.