For over 40 years, Ferno Australia has led the way in ambulance and safety supplies. When they needed a smarter solution to organise 29 electronic devices, they turned to Titan AV. Our task? Deliver custom-cut foam inserts that didn’t just meet the challenge—they transformed their ambulance operations.
The Mission
Titan AV's task? Create 30 custom foam inserts, each perfectly tailored to house 29 unique electronic devices. This wasn’t just about fitting gadgets into a box—it was about bringing order to the chaos of emergency response. We leveraged our CAD design expertise and CNC machine precision to craft inserts that maximise protection and efficiency.
Client Snapshot: Ferno
For decades, Ferno has been the go-to for Ambulance, Emergency, Rescue, and Height Safety gear. When they needed custom solutions for their portable equipment, they knew Titan AV could deliver. Our expertise in crafting high-quality cases with custom foam inserts has earned us a reputation for reliability across diverse industries.
Our Approach
Crafting 30 custom case inserts for Ferno required more than just cutting foam—it demanded precision, innovation, and a touch of Titan AV magic.
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Materials Matter: We chose high-density EVA foam for its durability and moisture resistance, coupled with 2.5mm aluminium plates for structural integrity. The inserts were housed in our rugged Titan AV 6003 Waterproof Cases, ensuring every device stayed safe and secure.
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Design Optimisation: Our CAD designer led the charge, iterating on designs until every piece of equipment had a snug, secure spot. The design wasn’t just about fitting devices—it was about making them easily accessible during critical moments.
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Local Collaboration: We partnered with Brisbane-based suppliers, including M-Coat Powder Coating, to ensure top-quality finishes. Supporting local businesses is a key part of our commitment to sustainability and community.
From Concept to Reality
Crafting these custom inserts was no small feat. It all started with rigorous testing, using scrap EVA foam to perfect the fit. Through over 45 iterations, we ensured that every cut was precise and each device was securely housed.
Maximising Space, Minimising Waste with Smart Design
Inside a compact 61-litre case, we needed to accommodate 29 different devices. Our solution? Custom aluminium trays with intersecting handles, allowing for efficient stacking.
We optimised every inch of material during CNC manufacturing, repurposing offcuts and prioritising recycling to minimise waste.
Assembling the Inserts
The assembly process was significant. The layers of custom sized foam and aluminium plates were methodically stacked and firmly secured together. The result was a robust yet lightweight structure designed to provide timeless protection for delicate electronic devices.
Overcoming Challenges
Even the best-laid plans encounter hiccups. Midway through production, a router bit snapped during the CNC cutting of aluminium parts. But our team swiftly adapted, updating the design to complete the run without losing materials or compromising quality.
The Results
The project yielded remarkable results:
- Enhanced Protection: Delicate electronics are now safeguarded against damage.
- Optimised Organisation: The smart design streamlines access, saving valuable time during emergency responses.
- Efficient Storage: Our custom inserts make the most of limited space, ensuring everything stays put during transit.
Lessons Learned
This project underscored the importance of precision and a methodical approach. We deepened our understanding of critical dimensions, which will inform our work on future projects. Titan AV's commitment to excellence, innovation, and Australian-made solutions was key to this success.
Ready to Transform Your Setup?
Titan AV specialises in crafting large-scale custom solutions tailored to your needs. Whether you're in AV, emergency services, or another industry, our custom foam inserts are designed to protect, organise, and elevate your gear. Due to the meticulous nature of our work, we focus on bulk orders of 10 or more units, ensuring both financial viability and top-notch quality. Contact us today to start your custom bulk project.