Heavy-Duty Touring Case for Line Array Systems
Case library / Pro audio / Heavy-Duty Touring Case for Line Array Systems
CASE STUDY 01 — Pro audio · Molded EVA · Waterproof · Shock absorption
Heavy-Duty Touring Case for Line Array Systems
A dual-layer EVA touring case for line array systems: 30% lighter than a plywood flight case, with reinforced corners, a molded internal suspension and superior waterproof performance.
PROJECT OVERVIEW
Line array systems travel between venues on a punishing schedule, and the client’s existing plywood flight cases were both heavy and prone to water ingress at the lid seam.
The brief was structural, not cosmetic: a lightweight yet impact-resistant shell that protects sensitive internal electronics from shock and moisture, inside standard air-cargo dimensions and within a single-technician lift weight.
1,200 sets
Units delivered
±1.5mm
Tooling tolerance
34 days
First sample to production
CHALLENGE
A shell that survives touring and still cuts 30% of the weight
Road touring punishes hardware: repeated 1.2 m drops, stacked truck loads, rain at load-in and condensation at load-out. The plywood cases protected the gear but added dead weight to every single load-in.
The electronics also had to be isolated from vibration without extra packing, so the suspension had to be part of the case itself rather than something assembled on site.
SOLUTION
Dual-layer EVA with a molded suspension core
We combined a thermoformed outer shell, a second EVA layer for stiffness and a custom-molded suspension frame that floats the electronics away from the walls. Every interface was validated before the steel tool was cut.
01
Dual-layer shell design
Outer shell and inner skin were modelled as one assembly so wall thickness, corner radii and lid overlap could be tuned before any tooling existed.
02
Suspension validation
A 1:1 printed suspension frame was drop-tested with real amplifier and processor weights, proving the rib pattern that carries the electronics before molding.
03
Reinforcement & sealing
Reinforced corner inserts and a gasketed lid overlap came out of the print feedback; the steel tool formed correctly first time and the first batch cleared the drop standard.
Printed suspension frame beside the final molded part: rib count raised from 6 to 9 and the drop standard lifted from 1.2 m to 1.5 m with no added shell weight.
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