Flight/Road Cases

Targeting custom case manufacturers, comprehensive design and manufacturing data generation solutions, supported by years of experience, knowledge, ongoing development, and technology.

Cases Designed

600+

Hours Worked

5000+

Clients Served

10+

Description

One of our design specialities is our road case and custom foam design solution, which we have created by working with designers and manufacturers all over the world. Understanding client needs is the first step in our comprehensive design service, which also includes providing ready-to-manufacture 3D models, thorough assembly drawings, and accurate NC codes for machining. Our solutions guarantee that each design is customised to satisfy particular requirements, maximising durability and functionality.

Additionally, we provide remote management and production scheduling to streamline operations. Even during busy times, orders are delivered as scheduled thanks to our adaptable resource management. Because of our flexibility, we can effectively manage a range of workloads and meet production deadlines without sacrificing quality.

We have created automation for CAD and CAM for cases operations, improving efficiency and dependability, thanks to our years of experience working with foam and plywood. Each case is expertly crafted thanks to these sophisticated automated procedures that speed up production and minimise human error. Our clients benefit from reduced costs and faster production times as a result of our automation expertise.

Through our consultation services, clients can take advantage of our wealth of expertise and experience, which offers insights and enhancements that can improve their processes and products. Allow us to assist you in optimising your transport case and road designs. Get in touch with us right now to find out how our customised solutions can satisfy your particular requirements.

Road Cases & Custom Foam

Case

The dynamic and demanding custom road cases and flight case industry necessitates operational excellence, precision, and inventiveness. This fast-paced industry pushes the limits of design and manufacturing due to its short turnaround times, varied client requests, and specific requirements.

Our quick and painstaking user-centric design process delivers well-made solutions that safeguard equipment, guarantee simple removal and replacement, ease transportation, and produce sturdy cases that can survive road trips and shipping tours. To make sure our cases are economical and long-lasting, we also place a high priority on economy and reusability.

We are excellent at cutting waste and speeding up machining in the manufacturing process to create reliable, high-quality products. Our optimised procedures guarantee effectiveness and uniformity in all facets of manufacturing.

Our success is largely due to our efficient management, which ensures that every department collaborates to meet deadlines and deliver work of the highest calibre. To surpass industry norms and customer expectations, we have perfected the art of striking a balance between creativity, accuracy, and efficiency. We've got everything covered!

Foam

The foundation of the road case design industry, foam is essential to the organisation and protection of products inside cases. In almost every situation, foam inserts are necessary, but they are especially important in stock cases made of aluminium or plastic injection moulding.

When designing foam inserts, it's important to balance protection, stock thickness, material selection, and spatial arrangement. In order to make sure the inserts are practical and easy to use, user experience and ergonomics are crucial. Unlike plywood, foam is soft and delicate, making custom foam machining a difficult task. To maximise effectiveness, quality, and minimise waste, it necessitates careful thought during the design phase and careful NC code generation.

We are skilled at striking this fine balance. We are your partners in overcoming these obstacles, providing creative solutions to guarantee that your foam inserts satisfy the highest requirements for organisation, protection, and user satisfaction.

Our Solutions

Our primary area of expertise is creating flight cases that ensure your priceless equipment will be as safe and functional as possible while being transported. Our all-encompassing strategy consists of:

Durable Construction: To ensure the safety of your equipment, we design strong cases that can endure rough handling and transportation conditions.
Material Expertise: Choosing high-quality materials to increase longevity and durability, such as plywood and impact-resistant plastics.
Interior Customisation: Modifying padding and foam inserts to protect contents from vibrations and shocks while maintaining their integrity.
Ergonomic Design: Truck-friendly sizing and precise-fit dimensions maximise handling convenience and spatial arrangement in a variety of situations.
Quality Hardware: Incorporating sturdy handles, wheels, and latches for safe and easy mobility.
Accessibility Solutions: Facilitating easy access with removable lids and panels for efficient equipment handling.
Weight Optimisation: Durability and portability are balanced for easy transportation without sacrificing security.
Aesthetic Enhancement: Presenting options for custom branding to strengthen your brand identity and improve visual appeal throughout every journey.

Our proficiency in flight case design and road case designer services covers a wide range of duties aimed at creating accurate and thorough models and drawings that are necessary for production and assembly. To assist clients in visualising and refining their ideas, we start with conceptual sketches or intricate 2D/3D renderings. Following approval of designs, we proceed to create accurate manufacturing drawings that carefully outline the components, measurements, and assembly guidelines. Each flight case is built according to precise specifications and industry standards using these documents as a guide.

Conceptual Drawings: Preliminary drawings or comprehensive 2D/3D designs to support the client’s comprehension and decision-making.
Detailed Manufacturing Drawings: Extensive specifications guarantee precise production information.
Accuracy and Precision: Thorough quality checks to get rid of manufacturing errors.
Collaboration: Close coordination with manufacturers and clients to improve designs in response to input.
Compliance: Assuring that every drawing complies with applicable industry standards, ensuring each flight case’s functionality and safety.

Our all-inclusive Computer-Aided Manufacturing, i.e., CAM for cases services, is designed to boost productivity and streamline production procedures in the flight case industry.

CNC Code Generation: We simulate and produce accurate CNC codes that direct machining operations for flight case components using sophisticated CAM software.
Nesting: To reduce waste and increase material utilisation, we carefully arrange component shapes on material sheets using cutting-edge nesting software.
Tool Library Development: We create and manage a strong tool library that guarantees reliable production quality and effective CNC machine programming.
Post-Processing: In order to improve accuracy and production efficiency, we can also create comprehensive post-processing instructions for CNC machines.
Offcut Management Processes: We employ customised strategies to maximise material utilisation and efficiently handle offcuts, lowering waste and operating expenses.

Our products are made to help companies in the flight case sector by offering economical ways to increase profitability through efficient production processes and optimal material use.

In the flight case industry, where precise orchestration guarantees on-time delivery and high-quality products, effective management is essential. Among our areas of expertise are:

Order Processing: By using cutting-edge project management tools, we streamline the ordering process and guarantee accurate and timely order processing.
Production Planning: We make sure that deadlines are met for on-time flight case deliveries by closely coordinating with your production schedules.
Inventory Management: We use your inventory software to make well-informed decisions on our own, freeing up your time for important business tasks.
Quality Control: To ensure that every flight case satisfies our exacting standards and surpasses client expectations, we implement strict quality checks.
Client Communication: We keep open lines of communication throughout the order cycle, giving you regular updates and quickly resolving any issues so you can focus on your top business priorities.
Relationship Management: We place a high value on enduring client relationships by learning about their particular requirements and providing tailored services that support company expansion.
After-Sales Support: As part of our proactive strategy, we effectively address post-delivery concerns to maintain client satisfaction and operational effectiveness.

For flight scenarios, we offer complete visualisation solutions that include interactive animations, finely detailed 3D modelling, and excellent photo-realistic renderings. Before placing orders, these services enable clients to precisely visualise and assess flight case designs, guaranteeing that they precisely match their unique needs and expectations. Rendering and animations also make an impact in e-commerce and marketing.

3D Modeling: Constructing detailed 3D models that display every facet of flight case designs, including material selections and dimensions.
Photo-realistic Renderings: Creating lifelike images that provide a precise representation of the final flight case.
Animations: Creating interactive animations that improve comprehension and usability by illuminating the flight case’s features and functionality.
Customization Options: Allowing clients the freedom to experiment with different customisation options, like distinct features and materials.
Client Collaboration: Working closely with clients to understand their particular requirements and preferences in order to make sure that visualisations appropriately represent the solutions they have in mind.

By enabling clients to make well-informed decisions, these visualisation services promote confidence and satisfaction in their flight case designs.

For 3D models of common parts needed to build flight cases, Keyway Engineering offers full database management services. Our design and production processes are guaranteed to run as smoothly and consistently as possible thanks to this service. Among the services we offer are:

Database Maintenance: To guarantee that the database contains the most recent additions and modifications, regular updates and accuracy checks are performed.
Additions and Updates: To guarantee that all necessary standard components are easily accessible for design and manufacturing, new components are added to the database as needed. Another important factor is backward compatibility.
NDA Compliance: Non-Disclosure Agreements (NDAs) are strictly followed in all database management operations to protect the privacy and security of proprietary data.
Pre-built Libraries: Access to pre-made 3D model libraries that speed up the design process by acting as a foundational resource.
Customization Capabilities: Options for altering pre-existing 3D models in the database to satisfy particular customer needs and tastes.

Effective database management supports the smooth production of high-quality flight cases by improving workflow efficiency, improving design accuracy, and maintaining confidentiality.

Automation

In the road case industry, automation greatly improves design for manufacturing stages by decreasing errors and boosting productivity by carrying away with repetitive tasks. Rule-based automation is essential because it allows computer algorithms to carry out predetermined tasks while requesting user input when needed. Reusing models that have already been built can significantly reduce the amount of time needed to design new projects. The limited range of materials and equipment used in CAM enables further custom road cases automation beyond what is possible with generic stock CAM packages, which are made to support a variety of industries. In light of this, we work with our clients to create custom automation solutions that optimise productivity and efficiency by seamlessly integrating with their unique workflows.

CAD Automation

Skeletal Modeling

We can efficiently create conceptual designs for client review and approval by using our skeletal models as references for different types of flight cases.

Parametric Design

In order to ensure that modifications are more accurate and efficient and increase our clients’ profit margins, we use parametric modelling techniques in our designs.

Macros

By leveraging the automation capabilities of CAD software and the APIs, we can create macros that expedite tedious and repetitive tasks, thereby boosting productivity.

Library Database

We have an advantage in design automation and reduce the time needed to bring the design to production, thanks to our large database of CAD components for flight cases.

Feature Automation

We can reduce the amount of repetitive component placement and feature applications by using built-in CAD features, which enable us to get to the manufacturing stage earlier.

Production Automation

We can effortlessly transfer flight case production details to ERP thanks to our CAD customisation. For start-up companies without access to costly ERP software, this solution is ideal.

CAM Automation

Toolcrib Library

Our resources can create a tool crib library that you can incorporate into your CAM program. We provide maintenance services for frequent updates to these libraries.

Post Processors

If the manufacturer does not provide post-processor files for a particular CNC machine, we can create them using our in-house expertise.

Feature Recognition

You will save time by not having to repeatedly recognise and program your components because our CAM database team can identify repetitive features in them.

Nesting

In order to maximise material utilisation, eliminate waste, and strengthen your profit margins, we work with a variety of nesting software.

CAM Macros

Setting up a CAM can be a laborious, repetitive, and time-consuming process. We use macros to expedite the process and get you to the part that needs your time the most.

Case Design Studies

Tabbed Interface

Side-Loaded Light Case

For one of the largest lights on the market, the Chauvet Maverick Storm 4, top loading is impractical due to the light's weight and size. Side loading, which necessitates a front-opening case, poses a challenge to maintain structural rigidity.

Taking on this challenge, we developed a case with an exceptionally robust platform to transfer loads as low as possible, preventing bowing of the sidewalls. The case also needed to be stackable, requiring a strong lid.

Our innovative design balances the protection of delicate equipment, ease of loading, and the durability needed for event transportation. This case demonstrates our commitment to creating solutions without compromise, ensuring both functionality and strength.

Surgical Bed Case

In a project extending beyond the use of plywood, we faced the challenge of designing a case for a 200kg surgical bed that required part of its base to slide out, leaving the remaining structure weakened. Ensuring the base stayed in perfect shape to slide the mammoth back in required an innovative structural engineering solution.

Our approach involved integrating a structural steel frame inside the case, connecting the side walls and the stationary part of the base rigidly. Precision was paramount since the extrusions enabling the sliding mechanism had to support the heavy load during forklift lifting.

Additionally, the three-piece caster board needed reinforcement. Through meticulous engineering and attention to detail, we achieved pinpoint accuracy, ensuring the case could withstand hundreds of unloading and transportation cycles, maintaining both structural integrity and ease of use.

Luxury Workstation

Our luxurious workstation case is a marvel of engineering and systems design, housing six screens on a motorized lift, a computer, a network switch, a sound system, a printer, and even a fridge. With nearly 200 unique parts, this project presented an exciting challenge. The rear of the case accommodates the motorized lift-mounted screens and a complex network of wiring, ensuring seamless connectivity for the front-mounted equipment. Each device has its own dedicated compartment, facilitating ease of use.

To enhance user experience, we developed a special mechanism to adjust the angle of the top row of screens for optimal viewing. Additionally, the three drawers are reinforced with extra slides to securely store heavy equipment. This meticulously engineered case not only ensures functionality and durability but also embodies the pinnacle of luxury and convenience in a mobile workstation.

Teleprompter Suitcase

Client requested a lightweight and compact teleprompter for easy transport by air. The challenge was to create a structurally sound platform for the display using lightweight materials.

Leveraging our expertise and structural analysis, we designed reinforcements in critical areas to ensure the case could support an adjustable-angle platform and endure hundreds of opening and closing cycles.

The final design is a suitcase featuring a TYPE-D input patch panel, accessory storage, and an adjustable-angle teleprompter, all weighing under 20kg!

Mixer Flycase

Our client, a touring musician, needed a flight-friendly case for their 9kg mixer. The case couldn't have a fixed castor board due to flying constraints, but the mixer’s weight made it impractical to carry around when not flying. Our solution was to design the case using lightweight materials and streamlined foam inserts that still ensured the mixer’s safety.

We incorporated a removable castor board with tight design tolerances to allow easy and repeated removal and replacement with minimal play. Remote coordination posed a challenge, but we successfully conducted tests with the on-site manufacturing team, achieving the perfect custom-fabricated catch plate within a tight timeline that didn’t permit iterations.

Stacked Speakers Case

Speaker cases are regularly needed in the entertainment industry. Modular concert speaker systems like the KARA II from L-Acoustics offer versatile setups, but assembling and disassembling them takes a lot of time. Our client requested a case to store stacks of their modular speakers instead of individual ones. The stack needed to rest on an inclined surface to stay straight and required an inclined support in the lid as well. We determined that a 3-high stack was the maximum possible without compromising stability.

Additionally, existing market cases lacked foam padding under the speakers due to the difficulty and cost of angling the foam correctly. We devised an innovative support structure in the base and lid, covering it with foam without leaving gaps for a seamless finish. The result was a superior, aesthetically pleasing case, and our client was thrilled with what we delivered—truly the best on the market.

Our Work

Our Process

Step 01

Client requirements

recognising the necessary case type, the equipment to be carried, the protected areas, the storage and size requirements, and the application areas.

Step 03

Client approval

After reviewing a number of options and assessing their advantages and disadvantages, the client can ultimately decide on a concept to approve and proceed with.

Step 05

CAM and Manufacturing Data

In order for the machine shop and the assembly team to prepare the flight cases, case detailing gives way to manufacturing drawings, panel layouts, QC checklists, production BOMs, and the creation of CNC files for lasers or routers.

Step 02

Case concept design

We are able to generate potential case concepts for the client to examine and approve based on the requirements by using CAD, images, and videos.

Step 04

Case detailing

In order to make the validated concepts manufacturing-ready, our team of engineers begins adding details. At this point, design and BOM optimisation happen at the same time.

Step 06

Manufacturing

After that, the assembly and manufacturing teams can work together to prepare the flight cases, making sure they match all of the manufacturing data that was supplied. After passing through the QC department, the flight case is transferred to the shipping department.

Contact Us

Send us an email @ info@keyway.com.pk using below form and/or set up a free consultation right from our website.

Book a free Consultation

If you have any questions, you think are best answered in an in-person meeting or would like to schedule a session with out experts to know how we can solve your problems, feel free to set up a meeting with us!