Custom protective packaging · Oak Ridge, Tennessee · Since 1991 (865) 481-3801
Vol Case, Crates & Cases

Custom industrial packaging

In-house design for cases, foam and crates

See the design before we build.

Vol Case provides protective packaging design for companies that need injection molded cases, ATA cases, wood crates or custom foam. We plan how your equipment will fit, be supported and be moved, then review the design with you before production.

Explore what we design

Free design & quoting. No obligation.

CAD rendering of a custom wood crate with a loading ramp and internal equipment supports.

Free design and quotes

Our design work and quotes are free, with no requirement to purchase.

Review before production

See the proposed packaging and request changes before you approve the build.

Designs kept for reorders

We keep approved designs and revisions for future orders.

Cases, crates and foam

What we design

We design complete cases and crates as well as foam inserts. The equipment's size, weight and use help us choose the packaging and the features it needs.

Injection molded case selection and interior design

We help select an injection molded case with room for your equipment, its accessories and the foam that supports them. We consider the usable space in the base and lid, the weight when packed and how the case will be carried or moved.

Inside the case, we plan where each item sits and how you will reach it. Foam pockets, layers and lid storage can keep parts organized, leave room around delicate features and make the equipment easier to pack and remove.

Explore injection molded cases
Open injection molded case with fitted foam pockets in the lid and base.

Custom ATA case design

We design the complete ATA case around your equipment, including its size, openings and interior. The design considers how equipment enters the case, how it is held during transport and whether parts need to stay accessible while the case is in use.

Depending on the equipment, we can include drawers, removable trays, partitions, shelves, restraints or ramps. We also plan how the loaded case will move between floors, vehicles and storage areas, with attention to repeated use and efficient packing in trucks.

Explore ATA cases
Open black ATA case with a divided interior and a detached side panel.

Custom wood crate design

Custom crate design starts with the base and the places where the equipment can be supported. We consider its weight, delicate surfaces and lifting points, then plan the supports, blocking, bracing and restraints that will hold it inside the crate.

The design also accounts for loading, unloading and the journey between facilities. Depending on the equipment, that can include saddles, skids, cushioning or waterproof barrier bagging. We can design a crate for a single shipment or for repeated use when needed.

Explore wood crates
Wooden shipping base with shaped upright supports and bolted mounting brackets.

Custom foam insert design

We design foam inserts as a standalone product or together with a case or crate. Each layout places support where the equipment can take it, leaves room around delicate parts and gives you space to grip and remove the items.

Material, density and color choices depend on the equipment, its use, cost and presentation. We plan the pocket shapes, depths and layers around current measurements, with a clear place for each component. For existing packaging, the foam must also fit the available interior space.

Explore custom foam
Custom foam insert with shaped equipment pockets and hand openings.

Getting started

What to send

You do not need a finished CAD model to start. Share the information you have, and we can identify what else needs to be measured or confirmed.

Files, photos or parts
Provide current 3D CAD models, assembly files, 2D drawings, measurements or photos. We can also work from a physical part; contact us to arrange it.
Equipment and accessories
List the items to be packed, their dimensions and weights, and how many of each belong together. Identify delicate surfaces, connectors and suitable support points.
Loading and use
Explain how equipment will be loaded and removed, what needs to stay accessible and how often the packaging will be opened or reused.
Transport and handling
Tell us how the packaging will travel and how it will be lifted or moved at each end of the journey. Include any limits on outside size.
Quantities and dates
Tell us the number of cases, crates or inserts needed and your target delivery date. Note any planned equipment changes or prototype review dates.

Before production

Review the design

We use SolidWorks, Fusion and Onshape to prepare 2D and 3D packaging designs. We choose views that help you check the proposed case, crate or foam before it is built.

Wood crate design with a lowered ramp, straps and internal equipment supports.
Crate design showing the loading ramp and equipment supports.
Rendered model of an open case with fitted foam.
Animated case and foam model for design review.

See the whole design

Drawings and rendered views show how the packaging fits around the equipment. You can review the overall size, supports and item locations without having to picture them from a written description.

See how the parts fit together

Exploded views separate the parts of the design so you can see their arrangement. Layer views show stacked inserts, while motion views can show how the packaging opens, loads or comes apart.

Rotate, measure and look inside

Your design review includes a link to the proposed model. You can rotate it, take measurements and use cross-sections to see inside, then send us your comments or requested changes.

Project-specific checks

Check loads, clearances and moving parts

Some projects need closer checks of how the packaging carries weight or how its parts move. We help determine which checks are useful for your equipment.

  • Check how a design responds to loads

    Where useful, we can use finite element analysis, or FEA, to model how a crate or support responds to applied loads. A load-displacement view shows where the model predicts movement under those loads and helps us review the design.

  • Check room and movement

    Clearance checks help us see whether equipment, supports and case or crate parts have enough room around them. Motion views can help check that an opening, tray or other moving part can follow its intended path.

Military and government projects: our team has experience with military packaging requirements, including testing, markings and labels. For qualifying projects, we can work with confidential technical information within our controlled unclassified information (CUI) enclave. Contact us to agree how information should be shared.

FEA load-displacement model of a crate base, with a color scale showing predicted movement.

Design, build and reorder

From first design to production and repeat orders

We work with you through the design, review and build. If your equipment changes, we update the packaging design before you approve it for production.

  1. Agree on the packaging

    We review the equipment and how it will be used, help choose the type of packaging and prepare the design and quote.

  2. Review and make changes

    You review the proposed design and we make the agreed changes. If a hands-on check would help, we can make a physical prototype, charged for and quoted separately.

  3. Approve, build and check

    Once you approve the design, we cut the foam, assemble the cases or build the crates. We then review the finished packaging for fit, access and practical use.

  4. Reorder or update the design

    We retain the approved design and its revisions for future orders. If equipment or accessories change, tell us so we can review and update the design before the next build.

Frequently asked questions

In-house design questions

A few practical details about getting started, reviewing a design and ordering again.

Yes. We can work from CAD models, drawings, measurements, photos or a physical part. If your files are incomplete, we can help identify the details that still need confirmation.

Tell us about your project

Discuss your packaging design

Ready to discuss a design? Tell us what your company needs to pack and when it is needed. We can help identify the information required to get started.

  • Free design and quoting
  • Direct access to our team
  • No obligation to purchase
Prefer to talk?(865) 481-3801

Start your project

Provide a general project description. Do not include CUI or export-controlled information.

PDF, images, CAD files, or ZIP. Up to 5 files, 20 MB each. ZIPs may contain up to 20 files, totaling 20 MB when opened. No password-protected or nested ZIPs.

Use non-sensitive sample files only. Do not attach CUI or export-controlled technical data. Contact our team to arrange an approved transfer method.