Optimizing Tool Storage and Transportation with Custom Foam Inserts

Challenge

A leading global aviation services provider approached us with a challenge to create a tailored solution for storing and transporting a specialized tool kit. The client required a precise and durable solution to ensure the protection and organization of these critical components during transit and storage.

The client sought a custom foam insert and case solution that would accommodate their tool kit, which includes various components of different shapes and sizes. The key objectives were to optimize space, provide easy access to the tools, and ensure maximum protection during transportation, while also streamlining inventory management to prevent lost parts from being left on the flight line.

Solution

  1. On-Site Measurements: We began the project by visiting the client’s location to measure the individual components of the specialized tool kit. This on-site assessment allowed us to capture the exact dimensions and understand the specific needs and challenges associated with the kit’s storage, transportation, and inventory management.
  2. CAD Design and Visualization: Back at our office, we utilized CAD software to create a detailed design of the foam insert and case layout. This design phase involved meticulous planning to ensure that each component of the kit would fit securely within the foam, with consideration given to ease of access, optimal use of space, and the ability to quickly verify whether any items were missing. Additionally, we incorporated finger slots and uniquely shaped cavities into the design, making it easy to remove parts regardless of hand size. The Pelican Storm iM2950 case was chosen as the perfect size to match the layout for these tools. This attention to detail ensures that each tool can be easily and quickly accessed during use, improving overall efficiency.
  3. Client Review and Feedback: Once the initial design was completed, we plotted the image and presented it to the client for review. This step was crucial to ensure that the design met the client’s expectations and requirements. Based on their feedback, we made any necessary adjustments to the layout.
  4. Custom Foam and Case Production: After final approval, we proceeded with the production of the custom foam insert and case. The result is a perfectly tailored solution that securely holds each component of the specialized tool kit in place, providing protection and ease of transport. The custom foam also makes it easy to conduct quick inventory checks, ensuring that no tools are left behind, thereby avoiding the risk of lost parts being left on the flight line. The finger slots and unique cavity shapes further enhance usability, accommodating hands of any size and allowing for smooth and easy removal of the tools.

Outcome

The completed custom foam and case design exceeded the client’s expectations. The tailored solution not only optimized the storage and transport of the tool kit but also enhanced the overall efficiency and organization of their operations. With the custom foam insert, the client can quickly and easily verify that all components are accounted for, significantly reducing the risk of misplaced tools and the potential for costly errors. The addition of finger slots and uniquely shaped cavities also ensures that the tools are easily accessible, improving workflow and reducing downtime.

This project highlights our commitment to delivering customized solutions that meet the unique needs of our clients. By combining on-site measurements, CAD design, and meticulous production, we created a high-quality foam insert and Pelican case that perfectly fits the specialized tool kit. The solution not only provides protection and organization but also supports efficient inventory management and user-friendly access, giving our client the peace of mind that their tools are secure, organized, and easily accessible. Our continued partnership with Pelican Products, Inc. provides us the opportunity to stand out as a preferred Technical Packaging partner, constantly customizing, optimizing, and mobilizing important and sensitive gear!