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EVA Cases: The Benefits of Using Thermoformed EVA

EVA Cases: The Benefits of Using Thermoformed EVA

EVA (Ethylene-Vinyl Acetate) cases are a game-changer in the world of custom case manufacturing, known for their remarkable versatility and adaptability. EVA cases stand out for their ability to be molded into almost any shape and customized to various degrees of hardness and density. Ideal for a wide range of applications, particularly in sensitive fields like medical equipment, EVA cases offer a perfect blend of protection, lightweight design, and aesthetic appeal. They offer a great canvas for branding, with options for color customization and embossing.

Read on to learn about the process of EVA thermoforming, and how they might be the perfect fit for your next carrying case design project! 

What is Thermoforming?

In the world of custom case manufacturing, the thermoforming process stands out as a cornerstone technology. Thermoforming starts with taking one of a wide range of materials — in our case, EVA (Ethylene-Vinyl Acetate) — and heating it to a pliable state. Once heated, this material is skillfully forced into a specific shape using a combination of precisely designed male and female metal molds. The result? Custom-shaped items tailored to our clients’ needs

Want an inside look into how we transform raw materials into crafted cases? Click here now.

What is an EVA Material?

EVA is Ethylene-Vinyl Acetate, a versatile polymer that exhibits a remarkable range of states and properties. EVA can come in many different forms, densities, and hardness levels. We generally use EVA in its foam or sponge form, which is particularly notable for its adaptability. EVA is very customizable, allowing for a broad spectrum of applications.

You can create a wide variety of performance characteristics when combining EVA with additives. For instance, certain additives can enhance EVA’s ability to absorb energy, making it ideal for protective purposes, while others can improve its heat conductivity, its cushioning and insulation features, and more. This flexibility in modifying EVA’s properties opens up a world of possibilities making it one of the best materials for use in custom and hybrid case manufacture.

Visit Wikipedia for a deeper understanding of the EVA technology. Click here to go there now.

How to Choose the Right Grade of EVA for Case Production

Every case serves a unique role, whether it’s safeguarding delicate equipment from temperature fluctuations and humidity, cushioning it against the jolts of movement and impact, or the rigors of harsh usage. EVA’s versatility allows us to fine-tune these protective properties. By choosing the right density, hardness, and ingredients, we can tailor EVA to provide optimal protection. For example, a higher-density EVA could be selected for its superior impact resistance, ideal for cases expected to endure frequent drops or rough handling such as those for use in EMS services. Alternatively, a case designed for sensitive equipment might utilize an EVA grade with enhanced thermal insulation properties, ensuring protection from extreme temperatures. In every scenario, the goal is to match the EVA’s properties with the case’s requirements, ensuring maximum protection and durability while maintaining the sleek, customizable aesthetics that EVA thermoforming allows.

Choosing the Right Coating for Your EVA Case

Selecting the ideal coating for your EVA case is a decision that hinges on the specific needs and intended use of the case. Each case has its unique demands. For example, a case containing medical equipment might require that it meet biocompatibility standards and also be very easy to clean, as well as stand up to repeated disinfection. Or, perhaps it’s a case for hardware and measurement tools. A case like that must withstand abrasion and aggressive use and a more rugged textile like polyamide (Nylon) should be used.

Your case’s functionality is key, but it should also look good. While your case is protecting your device, it’s also representing your brand. Each coating option brings its strengths, from protecting the case to extending its life and maintaining its appearance in various conditions. Therefore, understanding the specific requirements of the case’s end-use is vital in choosing a coating that aligns perfectly with those needs, ensuring that the EVA case not only meets but exceeds expectations. At Shell-Case we work with you to sketch a demo and ensure that we perfectly understand your needs and present you with all available options. 

Limitations When Producing EVA Cases

There are limitations to consider in the design and manufacturing process when using an EVA case. At Shell-Case, we carefully evaluate factors such as size, thickness, weight, and the level of protection required. For instance, the size of the case can limit the thickness and hardness we can achieve while still maintaining practicality and portability. Similarly, the desired level of protection and waterproof capability can influence the choice of EVA grade and the design complexity. A more rigid and hard EVA might offer better protection, but it could also increase the case’s weight, potentially impacting its ease of use and transportability.

The shape of your device also plays a role in coating material selection. Certain shapes may restrict our ability to use specific coatings. Despite these limitations, the benefits of using EVA for case production are numerous, offering a balance of durability, flexibility, and customization options. 

The Benefits of Using EVA Cases

EVA cases stand out for their blend of affordability and customizability. The relatively low tooling cost of EVA production tooling means you can tailor-make your case without compromising on size and shape, even in smaller quantities, without breaking the bank. The semi-rigid nature of EVA strikes the perfect balance between usability and protection. It’s more user-friendly and aesthetically pleasing than hard plastic, and its shock-absorbing qualities mean your devices are safer.

Another significant advantage is the branding potential. You can select a specific color, add your logo through embossing, and define the exact size and features of your case. This level of customization allows your brand to shine through. The overall affordability of EVA cases removes cost as a barrier, opening up a world of possibilities for bespoke design and brand expression.

Combining EVA with Other Technologies

The integration of materials like coated TPU enhances functionality and aesthetics, addressing unique challenges in various fields, from medical devices needing rigorous protection and compliance​​​​, to consumer electronics requiring delicate care​​. This innovative approach extends to optical and measuring devices, where EVA’s compatibility with other technologies ensures safety and accuracy, underscoring the importance of first impressions and the value added by a well-crafted carrying case​​​​​​.

Want to see our work in action? Check out one of our many EVA projects: click here.

Work with Shell-Case’s EVA-based Technologies Today

Shell-Case has over 15 years of experience producing EVA cases in all sizes, shapes, and colors. Reach out to us by clicking here now to share a bit about your upcoming project, and to learn more about which EVA case solution is right for you.

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