Design to dispatch, under one specification.
AirvexPro designs and manufactures through our Shenzhen-based production network: foam conversion, case fabrication and customisation, finishing, assembly and export packing — coordinated as one programme with one drawing set and one accountable contact.
CAD Design & Prototyping
Insert and case layouts modelled from your STEP/IGES files or measured samples. Cavity clearance, retention and foam wall sections are engineered before cutting. Prototypes are produced on the same processes as production, so the first article is representative.
CNC Foam Milling
Multi-axis CNC routing of EVA and PE foam for sculpted, stepped and multi-depth cavities — the right process for complex parts, prototypes and low-to-mid volumes where die tooling is not justified.
Die Cutting
Steel-rule die cutting for flat profiles, gaskets, lid pads and high-repeatability parts. Economical at volume, with tight profile tolerances across the run.
Waterjet Cutting
Cold, precise cutting of thick foam stacks and multi-material laminates without heat distortion or tooling cost — ideal for thick transport-case interiors and mixed-density stacks.
Lamination & Assembly
Multi-density foam lamination, skiving, edge finishing, and insert-to-case assembly including panel fitting, lid organisers and hardware installation — delivered as finished, ready-to-use units.
Flight-Case Fabrication
Laminated plywood panel cutting, aluminium extrusion framing, steel corner and latch hardware, castor and ramp fitting — transport cases fabricated to the drawing, not adapted from stock shells.
Case Customisation
Moulded and aluminium case programmes: shell selection, interior fitting, connector panels, pressure valves, wheel and handle sets, and identification — specified per project.
Thermoformed Trays
Formed trays and nests for returnable systems and presentation packaging, with stacking features and part-specific geometry.
Finishing & Export Packing
Laser engraving, screen printing, etched nameplates and handling marks; final QC, photo reporting and export-grade carton/pallet packing for international shipment.
One network, coordinated centrally
Protective packaging programmes fail at the interfaces — foam that almost fits the case, hardware that arrives after the interiors. Because design, conversion, case work and assembly are coordinated by AirvexPro against one drawing set, the interfaces are our problem, not yours. You approve one specification, one prototype and one quotation.
- Single drawing set governs foam, case and hardware.
- First-article inspection before production release.
- Photo QC reports before dispatch — see Quality Control.