XpertVR create VR equipment for the fire service, safety teams, and educators.
As they put it, their technology helps train firefighters using immersive VR headsets, preparing them for real-world scenarios before they ever step into them.
They came to us needing a custom foam packaging solution for their XpertFire.
Something that didn’t just protect components in transit, but could also stand up to repeated use, keep everything organised, and deliver an intuitive experience for anyone using the kit.
Their existing case wasn’t doing that.
So we stepped in.
The client’s original packaging had a number of issues that became more noticeable over time.
While it worked initially, it wasn’t built for repeated use.
The foam began to chip as components were regularly removed and replaced, leading to visible wear - and a less professional appearance.
The convoluted foam in the lid wasn’t properly secured, meaning it gradually detached with use.
Internally, the layout wasn’t optimised for the components.
Pockets didn’t fit properly, which led to:
In short, the case looked the part, but didn’t perform the way it needed to in the real world.
We redesigned the packaging from the inside out, our focus being on durability, fit, and usability.
As part of the design process, we used CAD modelling to map out the internal layout and ensure every component would be properly supported before production even began. This allowed us to optimise space, refine fit, and eliminate potential issues early on.
The solution we came up with uses high-quality crosslinked Zote foam. This material is known for its strength, clean finish, and long-term performance. Unlike the previous foam, it won’t chip or degrade with repeated handling.
Inside the case, we precision-engineered every cavity to fit each component exactly. This:
As you can see in these images we also added removable foam inserts within selected compartments to hold more delicate components securely in place.
Creating a foam set within the main foam insert isn’t something we do on every project, but in this case it gave the client an extra level of protection during transport and repeated handling, and also assisted with organisation for more fragile items.
Another detail the client particularly liked was the use of branded removable foam pieces in compartments that may not all always be in use. Rather than leaving empty spaces inside the case, these inserts keep the layout looking clean and complete while incorporating the XpertVR logo into the design.
We also reworked the inner layout to maximize the space within the client’s chosen NANUK case. Our new design was more compact and efficient with enhanced protection.
Old case
New case
The updated packaging resolved every issue with the original design.
The new Zote foam eliminates chipping and wear, giving the case a clean, professional look even after repeated use.
Components now sit securely in place, reducing movement and improving protection during transport.
The redesigned layout makes better use of space, keeping everything organised and easy to access.
And with a properly integrated convoluted foam lid, durability is no longer a concern.
The result is a packaging solution that doesn’t just protect the product, it improves how it’s handled, stored, and experienced every day.
One of the biggest changes in this project came down to material selection.
Switching to crosslinked Zote foam didn’t just improve durability, it elevated the whole look and feel of the case.
For products that are handled regularly, shown to customers, or used in the field, this makes a real difference.
Because packaging isn’t just functional - it’s a huge part of the product experience.
We’re thrilled to have received this feedback from XpertVR:
“We were excited to be working with a Canadian manufacturer and using a Canadian case via SmartShield and Nanuk. A major benefit of working with SmartShield was the ability to collaborate with your designers to allow for integrated charging cables throughout the case.”
Feedback like this highlights the value of our one-to-one design process, where our team works directly with customers to refine every detail before production begins.
If your current packaging is starting to show wear, lacks organisation, or just isn’t performing the way it should, it might be time for a redesign.
At SmartShield, we create custom packaging solutions built around how your products are actually used, not just how they’re shipped.