Custom Non-Standard Sizes All-Aluminum Trolley Cases

Real Case 1: Custom-Sized Check-In Case for an Emerging US Brand

Client Background: An emerging US brand needed a highly durable guitar hard case for musicians, with strong brand identity, capable of meeting international checked baggage standards.

Challenge: Dimensions of 132 cm in height and 40 cm in depth. The case must be scratch-resistant and withstand breakage or deformation during baggage handling, protecting the contents inside. The surface required an exclusive embossed texture with the brand's logo, and the lock needed to be TSA-approved.

Solution: We manufactured the shell using pure polycarbonate (PC) material and developed a scratch-resistant texture. A thickened aluminum alloy frame structure was designed for the case opening/closing mechanism. Two metal brackets were added inside the lid for reinforcement. Custom-shaped foam interiors were developed to secure the guitar. A built-in TSA combination lock was integrated as standard.

Results: The finished product successfully passed tumble tests. The initial order was 300 pieces, and the client has reordered multiple times over an 8-year partnership. Three additional sizes have been developed since then.

Real Case 2: Custom Premium Packaging Case for a Cross-Border Brand

Client Background: The No. 1 poker sales brand in Germany needed a custom carrying case for packaging poker chips.

Challenge: The case required an internal depth of 50mm, a premium appearance, and an exclusive embossed texture on the surface featuring the brand's logo.

Solution: We manufactured the shell using pure polycarbonate (PC) with a scratch-resistant texture. An ultra-narrow aluminum alloy frame structure was developed, paired with custom-fitted small locks, finished in premium black through anodizing. EVA and EPP foam interiors were designed to securely hold the poker chips and other items. Frosted plastic bags and high-quality rigid boxes were used for outer packaging.

Results: The finished product successfully passed all quality tests. The initial order was 1,000 pieces, and the client has placed multiple reorders over a 6-year partnership. Several additional sizes have been developed since then.

Real Case 3: Custom Premium Oversized Packaging Case for a Japanese Golf Brand

Client Background: A Japanese golf bag brand required a large transparent checked case.

Challenge: The case needed to be 1.6 meters in height, fully transparent, and feature the brand's exclusive embossed texture and logo printing on the surface.

Solution: We manufactured the shell using pure polycarbonate (PC) with UV printing for the logo. Standard YKK black zippers and HINOMOTO black silent spinner wheels were fitted to complement the transparent shell, achieving a premium aesthetic.

Results: The finished product successfully passed all quality tests. The initial order was 1,000 pieces, and the client has reordered three times since then.

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