Hundreds of critical military operations happen every day, and sophisticated military equipment is moved from one place to another in harsh environmental conditions. Protecting this critical equipment from damage necessitates durable, customized, and reusable packaging.

The defense sector needs protective packaging that combines robust mechanical structure, precise mounting and cushioning methods, and unique labeling and accessories. It must adequately protect sophisticated military equipment, including weapon systems, life-saving medical care kits, and cutting-edge communication equipment; all paramount to a military operation’s success.

Meeting this demand for sustainable protective packaging is Gemstar, an engineering-based solutions provider with over 55 years of manufacturing experience and industry knowledge. Family-owned and supported by a long-term workforce, Gemstar has a history rooted in custom manufacturing, matched only by its longstanding dedication to customer-centric service. These competencies make it the perfect packaging partner for the transportation of military apparatus.

“We constantly innovate our manufacturing capabilities and test the limits of plastic manufacturing to exceed the packaging expectations of our clients,” says Mark Hedin, Vice president of sales at Gemstar.

State-of-the-Art Molding Technology for Unparalleled Durability

This superior capability is backed by its exclusive Robomold® Technology, which grants Gemstar cutting-edge plastic manufacturing capabilities by use of its exclusive robotic rotational molding in addition to traditional rotational molding, injection molding, thermoforming, and cold forming. Gemstar is also equipped to facilitate the fabrication and finishing of the defense sector’s most complex and high-value protective packaging requirements.

Robomold Techonology, Gemstar’s robotic biaxial heat molding process, provides the ability to concentrate varied levels of heat into specific areas depending on the unique product needs. This proprietary robotic technology allows Gemstar to streamline its manufacturing process to produce protective packaging whose rugged specifications can easily withstand high-impact applications. The wall thickness of containers is customized per client requirements. The unsurpassed design flexibility of Robomold Technology allows Gemstar to layer different compounds and coatings into the containers.

High tolerance with precision-distributed heat and material control impart consistent part repeatability and optimized strength-to-weight ratios. Along with molding in metal inserts, logos and graphics can be embossed and debossed on the protective containers.

“Robomolding is an art when it comes to plastic manufacturing. It’s far more advantageous than any conventional molding technology as it can automate much of the hazardous manual work while bringing a greater level of manufacturing speed and quality,” says Hedin.

Hard Cases for the Most Demanding High- Impact Application

Gemstar’s highly efficient manufacturing has paved the way for robust protective containers; Stronghold®, Sentinel®, and VersaPro®.

The Stronghold hard cases are rotationally molded to be airtight and watertight, perfect for storing and transporting fragile military equipment. These double-walled, long-life, reusable containers are built with GSR™ resins to meet customers’ exacting specifications, including the MIL-STD 810F and military LLRC standards. They have a stackable design, which enables them to be stored and transported with ease.

The injection-molded Sentinel hard cases are best suited for customers looking for lightweight containers with high durability. Preferred for medical kits, these single-walled cases come with GSI™ impact-resistant resin, pressure relief valves, molded-in padlock brackets, ethylene propylene diene monomer (EPDM) gaskets, stainless steel hardware, and secure, easy-open latches.

Gemstar’s VersaPro cases are preferred by clients seeking customized interior design for high-volume projects to transport intricate components. Thermoformed and single-walled, these plastic cases use GST™ resins and have an aluminum tongue-and-groove enclosure with a flexible lid and base height option so that customers can adjust the case to their needs.

Gemstar uses foam as a cushioning material for case components because it is suitable for small and medium equipment with delicate to moderate fragility. For larger and heavier parts, where foam is not suitable, compression mounts and wire rope isolators are used for shock and vibration protection. Its rugged all-metal designs require no maintenance and are unaffected by chemicals, oils, ozone, abrasives, and extreme temperatures.

We constantly innovate our manufacturing capabilities and test the limits of plastic manufacturing to exceed the packaging expectations of our clients

Along with the basic design configurations of these product lines, customers can choose from hundreds of sizes and customization options to meet their exact storage and transportation requirements.

A Customer-Centric Collaboration Approach

Gemstar’s team interacts with the client to understand their product goals and objectives. A comprehensive assessment of the potential environment where the protective cases will be used enables it to determine the safety of the goods to be transported. Gemstar’s experts take client feedback throughout prototyping, testing, fabrication, and convenient in-house tool manufacturing. Testing ranges from submersion and vibration to fog and UV. These measures ensure a fail-proof production process and quick turnaround times.

Clients don’t have to depend on multiple vendors or disconnected supply chains for their varying packaging requirements. Gemstar can deliver products even during disruptive times, like the pandemic, which is one reason why it became a Tier 1 supplier for various government agencies. The protective cases and custom foam solutions have protected electronics on Mars Rover missions, transported critical military vehicle repair and maintenance kits, and housed U.S. Navy radio communications systems.

Moving ahead with its innovative streak, Gemstar will continue investing in cutting-edge fabrication technology to conform to evolving military requirements. Expanding its footprint with a second manufacturing plant will bolster its vertical integration capabilities and enable it to add new case sizes. The newly-added 20 different sizes can facilitate 96 different case configurations. With these capabilities, Gemstar aims to continue equipping clients with reliable solutions to enable them to adapt to grueling conditions while it keeps up with changing market demands.