How Are Pelican Cases Made? The Manufacturing Process Explained

When protection is critical, your gear deserves more than just a generic case—it needs purpose-built security. Pelican cases are synonymous with uncompromising durability and are trusted by professionals across defense, aerospace, industrial, and technology sectors. But what makes them so reliable? It all starts with the engineering behind how they’re made.

Pelican’s two primary case types—rotationally molded and injection molded—each offer distinct advantages based on the manufacturing process, material design, and end-use application. Understanding these differences is key to choosing the right solution for your mission.

Rotational Molding: Built for Rugged, Tactical Reliability

Rotationally molded Pelican cases are engineered for environments where failure is not an option. These are the cases you turn to when your gear needs to endure drops, vibration, extreme weather, and rough handling. Common in military and field applications, they’re designed and manufactured in South Deerfield, Massachusetts—and proudly made in the USA.

The Process

Each case begins with a hollow steel mold precisely engineered to reflect the final shape, including critical features like stacking ribs, recessed handles, and lid seals. The mold is mounted on a machine that rotates simultaneously on two axes. As the mold spins, it is heated in a large oven while plastic resin melts and coats the inner surfaces.

This process ensures uniform wall thickness, with 15–20% thicker corners and edges, where impact risk is highest. After cooling, the case is removed from the mold, trimmed, and hardware such as handles and latches is installed.

Why It Matters

Rotational molding produces a seamless, one-piece construction with no weak points. The tongue-and-groove design between the lid and base creates a tight seal for superior environmental resistance. These cases deliver high-impact durability, custom sizing, and multi-color availability, making them indispensable for tactical operations and heavy-duty use.

Injection Molding: Engineered for Precision and Efficiency

Injection molded Pelican cases are ideal for light-duty, high-volume needs—like storing cameras, drones, firearms, and sensitive electronics. These cases are manufactured in Torrance, California and South Deerfield, Massachusetts, and are the backbone of Pelican’s consumer and professional line.

The Process

Each case starts with a custom steel mold and a proprietary blend of high-performance polypropylene. This material is fed into a hopper, heated between 300°F to 550°F, and then injected into the mold under extreme pressure. Once cooled and solidified, the case is ejected, trimmed, and fitted with components such as watertight silicone O-rings, automatic purge valves, over-molded rubber handles, and stainless-steel hardware.

Why It Matters

Injection molding allows for precise dimensional accuracy, repeatable quality, and cost-effective mass production. With multiple stocked series—Storm, Protector, Air, and Vault—these cases are ready for immediate deployment, offering fast turnaround and dependable protection for lighter equipment.

Choosing the Right Case for Your Mission

At Custom Case Pros, we bring technical clarity to complex decisions. Whether your priority is shock resistance for military-grade hardware or sleek portability for sensitive tech, we help you determine the best match between rotationally molded durability and injection molded efficiency.

We also go beyond stock options by offering custom foam interiors, case branding, and hardware modifications tailored to your operational needs. Every element is engineered for purpose, precision, and professional presentation.

Let’s Talk Protection

You’re not just protecting equipment—you’re protecting uptime, reputation, and mission readiness. If you’re evaluating Pelican case options or need guidance for a custom solution, start a conversation with our design team. We’re ready to assess your project and engineer a case solution that meets your specs—and exceeds your expectations.

When your mission demands protection, we deliver precision—case by case.