Impact Cases designed and manufactured a shipping case for a leading defense contractor who produces specialized electro-optic systems, which are ultra sensitive to shock. Achieving demanding drop test scores was a compulsory part of the project.

The Industry: Defense

Application: Impact designed, manufactured and drop tested a shipping case that would protect delicate electro-optic systems that were extremely sensitive to shock.

The Challenge:
Foam cushion systems are typically designed for shock attenuation in the range of 15-80g at drop heights ranging from 12 – 48 ins. The customer’s engineering department wanted Impact to design and manufacture a case and foam system that would yield less than 10g peak deceleration during flat and corner drops.

The Solution: After a development period of 2 months, a final design was reached, which consisted of inner and outer cases manufactured from aircraft grade aluminum. The inner case converted the complex geometry of the delicate payload to that of a cube using a foam block system and a custom CNC machined foam insert. This inner case was placed within the outer case, and rested on a series of custom profiled foam blocks 6 ins. thick.

Defining Features: Two aircraft grade aluminum cases and a foam block system working in tandem with a custom CNC machined foam insert.

Benefits: The customer received a case that exceeded their requirements on a repeatable basis. Impact has been this particular customer’s ongoing supplier for over 20 years, and has in effect, become an extension of the firm’s engineering department.