Vacuum Thermoformed Cases With Custom Options

The vacuum formed case is the jack of all trades in hard shell cases.

Impact Resistant. Chemical Resistant. Extremely Customizable. Cost Effective.

Specific Applications for Vacuum Formed Cases

Vacuum thermoformed cases are great for tool storage, with customizable tool organizing pallets available.

You could use it as a base for a carrying case, with a custom foam interior, or a hybrid of the two interior styles.

Additional uses:

Shipping cases when IP rated water intrusion protection is not required
Custom tray inserts for any case (including Pelican™ cases)
Housings for devices
Other custom products on a contract basis

Whatever suits your needs best, vacuum thermoformed cases are a resilient option for your products and environment.

How Vacuum Thermoforming works at CH Ellis

Made by heating sheets of plastic, then drawing over or into a mold with a powerful vacuum. The primary materials used are High Density Polyethylene (HDPE), which is the same material used for truck bed liners, and Acrylonitrile Butadiene Styrene (ABS), for a more refined look.

Vacuum formed cases are often lighter, and more space efficient than similarly sized injection molded cases.

At CH Ellis we have two types of vacuum thermoforming.

Maac Comet shuttle machine: offers state of the art control for complex shapes and deeper draws
Koehring Brown rotary thermoformer: provides speed for less demanding applications

Chicago Case by CH EllIS

We mold all our vacuum formed cases in-house in Indiana. With over 100 molds to choose from, we can often create an optimal custom size and solution for your application with no tooling costs.

Many of our cases feature:

Gasketed interlocking aluminum valances with custom colors
Military style twist lock butterfly latches, or all metal briefcase style latches
Metal spring loaded carry handles, or briefcase style post mount handles
Externally mounted, field replaceable telescoping handles
Proprietary inline skate wheels with an average heavy-use expected lifespan of 10 years. And when they do wear out, they are field replaceable
Some cases feature molded corner bumpers that protect hardware from damage and prevent scratching of the surroundings

See Chicago Case

Create a Fully Custom Case

Our team can design a vacuum thermoformed case tailored to your specific needs, including options to mold in your brand design.

We’ll coordinate with you on all aspects of your design, concept, build and through to production.

You can own your own tool, and we offer options to amortize tooling expenses over the course of production.