Our Design Principles

At Armor Cases, every custom case design we create must pass a rigorous internal checklist to ensure it’s functional, durable, efficient to build, and delivers the best possible user experience. Our design principles are grounded in real-world use, manufacturing efficiency, and a commitment to quality.

Presentation Matters

A case should not only be functional, it should look professional and appealing to the customer. Design decisions such as using larger, cleaner foam cutouts over small, blocky inserts can elevate the visual quality without significantly increasing cost.

User-Friendly Design

We design with real-world usability in mind. Each case is thoroughly reviewed in CAD to simulate actual handling and use. This includes checking that:
• Handles are properly placed and accessible
• The height and depth allow for easy access to contents
• Lids, hinges, and compartments function as intended
A great case works just as smoothly in reality as it does in the design software.

Workshop Efficiency

Efficient manufacturing is built into every design. We strive to minimize workshop time without compromising quality by:
• Reducing complex or excessive foam cutouts
• Preferring symmetric parts for easier assembly
• Making similar parts clearly distinguishable to avoid confusion
Labor time often outweighs material costs, so we prioritize designs that are efficient to build, not just cheap to make.

Part Minimization

We aim to minimize both the number and types of parts used. For example, if the case is primarily built with 12mm panels, we avoid introducing 9mm panels unless absolutely necessary. This consistency speeds up cutting, reduces errors, and simplifies inventory management.

Durable, Low-Maintenance Construction

Designs are stress-tested for real-world abuse:
• If a case will be handled by forklifts, we avoid delicate components like mini castor boards
• For air freight or courier handling, we avoid easily damaged features like plastic feet
We consider how the case will be used, moved, and stored—then build accordingly.

Material Availability

Designs should use materials that are readily available. Out-of-stock or specialty components can cause production delays and unnecessary admin work. Unless there's a compelling reason, we use materials that are consistently in stock.

These principles ensure that every Armor Case delivers on quality, function, and craftsmanship from design concept to real-world performance.