In the world of bags, we often talk about protective cases for laptops, cameras, or everyday items. But when your “item” is a uniquely shaped, high-value robot, everything changes. Off-the-shelf bags simply can't provide the precise fit and reliable protection required, while any impact during transportation could lead to irreversible damage.
This was exactly the challenge one of our recent clients faced. They needed a custom-designed backpack for an advanced half-body robot. Before coming to us, they had spent 8 months approaching countless bag manufacturers but never found a solution that truly met their demand. For us, however, challenges like this are a reflection of what we’ve been solving for customers over the past 30 years - unique, complex, and highly specialized requirements.
Today, let's walk you through this real case and show how we transformed the client’s ideas and needs into a fully realized protective backpack.
The client's robot consists of the head, neck, and upper torso - an irregular shape with a center of gravity completely different from conventional items. The robot itself weighs 5 kg, and with a laptop, cables, and other accessories, the total load reaches around 10 kg. The client required the backpack to meet the following criteria:
• Lightweight materials: The backpack must be water-resistant and as light as possible to ensure comfortable carrying.
• Size compliance: It cannot exceed airline cabin luggage dimensions so it can be taken onboard as carry-on luggage
• Full cushioning: External impact must be effectively absorbed without transferring force to the robot; once loaded, it must also withstand low-height drop tests.
• Precise fit: The interior structure must follow the robot’s contours to avoid pressure points, squeezing, or surface scratches.
• Accessory organization: A dedicated area is required to store accessories other than the robot, ensuring everything can be arranged neatly.
Clearly, no off-the-shelf packaging or bag solution could meet these requirements. The only viable path was a fully customized design.
• 3D Modeling:
To ensure a perfectly accurate fit, a 3D file of the robot was essential. Using an industrial-grade 3D printer, we produced a full 1:1 replica of the robot. This allowed our pattern makers to intuitively understand every curve, angle, and contour of the structure.
• Virtual Simulation:
At the same time, our engineers conducted virtual assembly and stress simulations on the computer. This helped us anticipate possible issues during transportation and optimize the design from the very beginning.
To achieve full protection, a custom-molded protective shell is essential. After completing the robot’s 3D model, we created a dedicated mold based on precise measurements. Using high-density flame-retardant PE foam and EVA foam, CNC cutting allowed us to sculpt perfectly matched cavities for the robot’s head, neck, and shoulders. The resulting shell contours seamlessly around the robot, with reinforced ribs added at key stress points - forming a truly custom “form-fitted inner cradle.”
Material Selection:
We chose a dust-resistant, stain-resistant, and water-repellent nylon fabric, laminated with ultra-rigid EVA foam. This combination ensures that the protective shell offers outstanding compression resistance and impact absorption.
Once the robot is placed inside, its key areas are securely and gently wrapped, achieving zero movement during transport. The hard shell absorbs external impact, while the interior provides the refined, precision-level protection that truly matters.
To maintain this level of safety, accessories such as power cables, adapters, and other components must also have their own designated compartments. This not only keeps everything neatly organized but also prevents any possibility of friction or collision between accessories and the robot itself.
Designing a custom backpack for a half-body robot is only a glimpse of what we can do. We specialize in creating tailored carrying solutions for all types of special equipment. Over the decades, we have built custom bags for musical instruments such as guitar cover bags, wheeled hard-case bags for computers used by the visually impaired people, protective bags for cleaning machines, soft golf bags, medical equipment bags, and more, ensuring every product receives the most favorable protection.
From professional testing instruments, drones, and precision devices to medical equipment, film gear, and specialized tools, our custom solutions support a wide range of high-value and uniquely shaped bags customization.
We provide designs in soft cases, hard-shell cases, and semi-hard-shell constructions. Options include telescopic handles, wheels, and diversified harness systems to suit different carrying scenarios.
Functional compartments, shock-absorbing padding, cable-management sections, and wet–dry separation layouts ensure that every item inside is stored securely and in perfect order.
We offer screen printing, various embroidery methods, laser engraving, patch labels, and a full range of logo applications that combine aesthetics with professional craftsmanship.
Our bags can be engineered to meet IP67 waterproof & dustproof levels, anti-vibration requirements, drop protection, and other demanding environmental conditions - ensuring safety and reliability in any situation.
A well-designed bag is an “invisible guardian" - a silent protector throughout the entire lifecycle of your product, giving users complete peace of mind wherever they go.
Whether you need to protect a precision robot, a one-of-a-kind instrument, or equipment with a highly specialized form, we look forward to becoming your trusted partner in creating its custom “mobile home.”
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