Developed in the late 1930s, blow molding is a manufacturing process that is used to form hollow plastic parts. It is most commonly used to make plastic bottles. In principal, the basic blow molding process is similar to glassblowing. Plastic resin (pelletized raw plastic material) is melted and formed into a hollow tube or parison which is then placed into a mold. The parison is then inflated using compressed air to form a finished part.
In the early 1960s, PFC founder Peter T. Schurman realized that he could combine two hollow blow molded parts to form the lid and base of a portable container or enclosure, and the “double‐wall blow molded carrying case” was born.
Compared to many other industrial operations, blow molding double‐wall cases is a surprisingly simple process, yet one that yields amazing possibilities.
PFC cases are made of high density polyethylene (HDPE). Polyethylene is the most common of all plastics. It is frequently used to make plastic bags, plastic bottles, and food containers. As a thermoplastic, it softens and becomes pliable (and moldable) when it is heated, and it hardens and becomes rigid when it cools.
Because integrally molded interiors are part of the case structure itself and not glued or snapped in later, the overall case is stronger and more shock absorbent.
The air space between the double walls prevents shocks to the case exterior from being transferred to the case interior – providing superior case protection.
The exterior and the interior of a double‐wall blow molded case are molded as a single piece. That means that an interior designed specifically to package your product is integral to the overall structure of the case – not a separate insert that is made separately and installed later. That makes them surprisingly affordable.
The air spaces between the double walls are extremely useful. In the top or “lid” of a case, that air space is often used to store product manuals, forms/checklists, and marketing materials. In the bottom or “base” of a case that air space is an ideal place to store ancillary items – things like cables and hoses can be easily “stuffed” into a cutout to hold them securely in place. Impacts to the case exterior are not immediately transferred to the case interior.
Visualize what happens inside the mold: Imagine holding a deflated balloon between your thumb and forefinger and lowering it down into a large glass jug. If you then blow up the balloon, the balloon will fill the jug and take on its shape.
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