Rugged storage cases play a vital role in the military, providing secure protection and transportation for a wide range of portable equipment, from communications systems and UAVs to battery energy storage units. With modern technology becoming smaller, lighter, and more sensitive, these cases must offer more than impact resistance. They must deliver complete protection against dust, water ingress, UV, ozone, vibration, and extreme temperature cycles to ensure mission-critical electronics remain fully operational in any environment.
Challenge
An OEM specialising in military storage solutions approached Silicone Engineering to address the sealing needs of their ruggedised case range. The cases were designed to withstand the toughest environmental and climatic conditions, meeting standards such as MIL-STD 810 G, Def Stan 81-41, and STANAG 4280.
To achieve this, the customer required a sealing material that would:
-
Provide reliable long-term IP-rated protection against dust and water ingress.
-
Withstand UV and environmental ageing without degradation.
-
Perform across a wide temperature range, maintaining flexibility and resilience.
-
Endure repeated lid closures without losing compressibility or sealing capability.
Solution
Following consultation, Silicone Engineering’s material engineers recommended the use of expanSil™ closed-cell silicone sponge cord as part of the case’s closing seal mechanism.
Key benefits included:
-
Excellent compressibility and recovery – ensuring a uniform seal even under repeated compression cycles.
-
Low compression set – maintaining reliable long-term performance.
-
Environmental durability – resistance to UV, ozone, and moisture.
-
Temperature stability – flexibility from sub-zero conditions to high solar load exposure.
The cord was easily integrated into the case groove, providing a continuous barrier that met the IP65/IP67 dust and water protection requirements.
Results
The expanSil™ sponge cord solution enabled the OEM to deliver storage cases that:
-
Protected sensitive portable electronics, including communications, UAV, and battery energy storage equipment.
-
Achieved compliance with military sealing and protection standards.
-
Ensured long-term reliability across the most demanding operating environments.
By combining rugged polymer construction with advanced silicone sealing technology, the cases provide total environmental protection, securing the next generation of military electronic systems in the field.
