Most case companies employ this “traditional” method of
customizing case interiors. Ideal for low quantity applications requiring protection of a small number of components. Typically involves a foam lining with strategically placed foam blocks to secure the components within the case.
Pros: It
gets the job done.
Cons: Inexperienced individuals generally
produce an unprofessional looking job. Blocks tend to break off due
to insufficient adhesive or aging of substandard adhesive.
CNC ROUTER / MILL
A CNC router cuts / mills the foam to yield a foam
insert with comprehensive complexity. The cut foam layers are then
laminated to assemble the complete insert. Total control over cavity
shape and depth is achieved with this method. Ideal for small to moderate
quantity (up to 500) applications, this method yields high aesthetics
and precision repeatability.
Pros: Ability
to cut complex geometry - precise shapes and depth Guaranteed repeatable
results with high aesthetics
Cons: Non-Recurring-Engineering
(NRE) and setup charges are applicable.
CNC WATERJET
A CNC controlled nozzle directs a fine bead of high
pressure water to cut the foam. The cut is
straight through and thus the machine has no control over cavity depth. Cavity
depth is achieved by removing the block (cut by the waterjet), trimming and
reinserting it into in the cavity. The cut foam layers are then laminated to
assemble the complete insert. Ideal for small to moderate quantity (up to 500)
applications, this method yields high aesthetics
and precision repeatability.
Pros: Ability
to cut complex geometry - precise shapes (not depth) Guaranteed repeatable
results with high aesthetics
Cons: Non-Recurring-Engineering
(NRE) and setup charges are applicable.
DIE STAMPING
Foam layers are cut with a steel rule die then
laminated together. The cut is straight through and thus there is no
control over cavity depth. Cavity depth is achieved by removing the block
(cut out by the die), trimming it and reinserting in in the cavity. The
cavity walls will have a concave profile with each foam layer resulting
in an unappealing “ribbed” effect. Ideal for large quantity
(over 500) applications, this method is “tried and true” for
large scale production.
Pros: The most
effective and economical approach for high volume production requirements.
Cons: Non-Recurring-Engineering
(NRE), tooling and setup charges are applicable.
Design changes result in substantial tooling charges and lead times.
3455 14th Avenue, Markham, ON CANADA L3R 0H4 • Toll Free: 1-800-881-7544 • Phone: 905-470-7888
Email: info@impactcases.com