Case Study: A Custom Medical Crate That Delivered More Than Just Protection

At SmartShield, we love a challenge, especially the kind that pushes us to think creatively and collaborate across our teams. That’s exactly what happened when a leading Canadian medical device company reached out to us with a very specific and technical need: A tough, reusable crate that not only kept their sensitive equipment safe but also looked sharp when it landed in front of their customers.

This wasn’t just any box. It was a next-level medical custom packaging solution, involving complex foam engineering, a custom wooden crate, and a design that could protect, impress, and perform every time. Let’s take a look…

Understanding the Medical Packaging Client’s Challenge

From the beginning, we knew this project would demand precision. The client’s current packaging system had limitations, and they needed something more efficient and refined, not only to improve protection during transport, but to present their medical device in a way that reflected the quality of their brand.

As Ben from our team put it best: “We like it when our customers challenge us!”

The client was looking for a reusable custom crate with precision foam inserts and smart features - something we’d have to engineer from the ground up.

How We Solved It with a Custom Packaging Solution

We started by going straight to the source. Ashley, one of our technical specialists, visited the client’s site and took detailed measurements of the client’s equipment and previous packaging solution.

Using both as a reference, we recreated a design in CAD software, making sure we captured every angle and dimension accurately. To confirm we were on the right track, we built a first-off prototype crate, and worked closely with the client to fine-tune the fit.

Once the structure was confirmed, the next step was bringing the interior to life.

That’s where our foam department got to shine. Haley explained:

“Detailed foam sets are what we enjoy creating most. The components were cut on our water jet, heat-sealed for a perfect fit, and then passed along to our wood team for integration.”

Meanwhile, Brandon. from our production crew helped bring it all together with a custom packaging solution - a crate design that was as clever as it was robust. “These heavy-duty reusable crates were designed with a ramp that doubles as a lid,” he said. “Once the foam sets were installed, we added the removable panels and secured everything with the right hardware.”

Every part of this custom wooden crate was carefully considered, from the way the foam hugged the device, to how easily it could be opened, repacked, and reused without compromising the integrity of the contents.

The Result: A Next-Level Custom Packing Solution for the Medical Industry 

The finished custom packaging solution checked every box. It protected the device, streamlined the client’s shipping process, and gave the final package a polished, professional look that reflected the quality of what was inside.

“The result? A happy customer,” Ben said. “It’s always a rewarding moment when we create something that not only impresses our customer, but also improves their efficiency and the appearance of their packages.”

Looking Ahead

This project is a great example of what can happen when a client trusts us to go beyond the basics. Whether it's reverse engineering a legacy package or building something entirely new from scratch, we take pride in turning challenges into custom packaging solutions that perform, protect, and elevate.