Custom Case News
Beyond the Mold: Custom Sizing with Pelican™ Cut and Weld Cases
When it comes to transporting mission-critical gear, off-the-shelf sizes don’t always make the cut. But that doesn’t mean you need to start from scratch with an expensive custom mold. Thanks to Pelican™’s proprietary Cut and Weld process, you can achieve custom-sized and oversized protective cases with the rugged reliability of a rotomolded shell—without the long lead times or tooling costs.
At Custom Case Pros, we proudly offer this advanced modification process to help our customers meet their exact protection needs. Whether you’re housing turbine engines, UAV wings, satellite components, or sensitive comms gear, Pelican’s Cut and Weld technology opens the door to rugged customization like never before.
What Is the Pelican™ Cut and Weld Process?
Pelican’s Cut and Weld process allows us to cut and fuse existing Pelican™ rotationally molded single lid cases into new dimensions. By joining one or more cases using a precision-melted polymer rod, we create watertight, structurally sound joints that are often stronger than the original case wall.
This is not a bolt-on solution. It’s a true fusion process that chemically bonds the plastic, ensuring:
-
Full environmental sealing
-
Enhanced durability and load strength
-
Seamless aesthetics and structure
You retain the proven toughness of a Pelican™ case—just in a size that works for you.
Related: Explore Our Pelican™ Single Lid Case Options
🛠️ Why Choose Cut and Weld?
Cut and Weld is the ideal solution for oversized or odd-shaped equipment when time and budget won’t allow for custom molds. Here’s what makes it a standout:
Faster Turnaround
No mold creation = no tooling delays. We can cut, fuse, and deliver a fully modified case in a fraction of the time it would take to develop new tooling.
Cost Savings
By using Pelican’s existing single lid case inventory, we reduce materials and manufacturing complexity—saving you time and money.
Field-Proven Durability
Rotomolded Pelican™ cases are engineered for harsh use, and Cut and Weld cases are no exception. They maintain impact resistance, weather sealing, and stacking compatibility.
🧠 Engineered with Precision
With 300+ years of combined engineering experience on staff, our team doesn’t just modify cases—we engineer solutions. Every Cut and Weld case is designed for:
-
Payload protection
-
Shock and vibration mitigation
-
Transport safety
-
Field usability
We work hand-in-hand with your specs and constraints to ensure the case meets your operational needs—whether it’s flying cargo or rolling onto a military base.
📋 Getting Started: What We Need for a Cut and Weld RFQ
To deliver an accurate quote and case recommendation, here’s what we’ll ask:
-
What are the internal dimensions required?
(Length × Width × Depth — including lid + base) -
Can your specs vary slightly for cost efficiency?
A small adjustment may allow us to use a more standard base case. -
Do your dimensions need to be exact?
If your project requires tight tolerances, we may recommend a different solution like a new mold or an alternative product.
Related: Watch the Cut and Weld Video on Our Custom Solutions Page
📦 Real-World Excellence: Pelican™ Case for a Turbine Engine
Even years ago, Pelican was setting the gold standard in custom-engineered packaging. One archived project involved the transport of a high-value turbine engine, and the design showcased just how far Pelican™ protective solutions can go.
The case was equipped with:
-
Heavy-duty lifting rings
-
Reinforced metal handles
-
External document port
-
Desiccant and humidity indicator ports
-
A viewing port for inspection
-
Custom stenciling
-
A fabricated metal cradle
-
Elastomeric shock mounts
This combination of rugged materials and intelligent design ensured that the engine arrived safely and in perfect condition—demonstrating the level of attention to detail and protection that our team and Pelican bring to every project.
Fusion You Can Trust
Unlike cases that rely on bolts, glues, or mechanical fasteners, Pelican’s Cut and Weld process uses a precision thermal fusion method. A polymer rod is melted directly into the plastic at the seam, forming a chemical bond that is:
-
Watertight
-
Durable under stress
-
Resistant to impact, warping, or cracking
Each weld is performed under tight quality controls by trained technicians to meet or exceed military-grade durability standards.
Complete Protection with Custom Foam Interiors
Every custom shell deserves a custom interior. Our team designs tailored foam inserts for each Cut and Weld case, ensuring optimal fit, protection, and usability.
We offer:
-
Removable trays
-
Laser-cut label markers
-
Shock-mount bases
-
Water-jet cutouts
-
HDPE reinforcements
…and more, all designed to match the fragility, layout, and transport needs of your specific payload.
Is Pelican™ Cut and Weld Right for Your Application?
Consider this solution if:
-
Your payload is longer, taller, or deeper than off-the-shelf options
-
You need low to mid-volume units
-
Your timeline or budget doesn’t allow for custom molds
-
You require the toughness of a rotomolded Pelican™ case with more flexibility
It may not be ideal for extremely tight tolerances or high-production volume—where a new mold might be the better route. But for most custom and oversized use cases, Cut and Weld is the perfect middle ground between off-the-shelf and full-custom.
👋 Let’s Build Your Custom Case
Your mission deserves a case that fits—literally. With Pelican’s Cut and Weld process and our expert engineering team, we’ll deliver a protective solution that’s as tough as your gear.
Ready to get started?
Submit your specs or ask a question anytime. We’re here to help.
Protect your investment. Customize with confidence. Choose Cut and Weld.