Surgical headlights are critical tools in the operating room – precision-focused, portable, and expected to perform flawlessly. When Integra and Priority Design needed a custom carrying solution for its advanced OR headlight system, it partnered with Shell‑Case, experts in developing cases that protect delicate medical technology without slowing down clinical workflow.
We delivered a tailored solution that integrates ultra-light material with exact-fit interior design, featuring lightweight, durable materials built to support sterile environments. The result is a professional-grade case that safeguards Integra’s headlight system in storage, in transit, and during every stage of surgical preparation.
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The outer shell of the case is crafted from polycarbonate, offering a lightweight yet exceptionally strong barrier against impact, scratches, and external contaminants. Its sleek design reflects a professional medical aesthetic while withstanding the daily usage of a medical environment. This material selection ensures long-lasting durability without compromising portability or appearance.
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Inside, the case features a custom foam layout made of expanded polypropylene (EPP), designed to precisely fit the OR headlight, control unit, power supply, and all accessories. EPP not only provides excellent cushioning but also allows excellent cleanability—an essential benefit in medical environments. Each component is cradled securely in place to prevent shifting or damage during transit. The thoughtful internal structure supports quick access and efficient repacking.
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An integrated structural layer made of polypropylene (PP) enhances both functionality and aesthetics. This internal layer supports high-quality printing, offering clear visual guidance for component placement and organization—ensuring each item is stored securely and intuitively. In addition to its functional role, the PP layer contributes to a clean, refined interior appearance.
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Shell‑Case combines sustainability with high performance. The case is built from two primary materials: a polycarbonate outer shell and a polypropylene (PP) interior. Both components are RoHS and REACH compliant, fully recyclable, and designed for easy separation to facilitate individual recycling. Engineered for long-term durability, the case minimizes the need for frequent replacements and promotes an environmentally responsible product lifecycle. It’s a smart, sustainable choice for medical companies seeking to lower their environmental impact without compromising on quality or regulatory compliance.
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