Custom military packaging starts with clear requirements. Faes turns them into a design that is tested and documented. The result is a production-ready solution that demonstrably meets the requirements.
Summary of this article
Developing military packaging does not start with choosing a case, material or standard. For us, it starts with the equipment that needs to be protected and the conditions in which it will be transported, stored and used.
That distinction matters. A maintenance kit that is opened daily at an airbase places very different demands on its packaging than communication equipment that must remain operational in extreme conditions. And an aircraft component several metres in size requires a completely different approach again.
That is why we work at Faes from one clear principle: understand first, design second. Based on a clearly defined set of requirements, our packaging experts, engineers and production specialists work together towards a solution that not only fits, but also performs as required in practice.
A reliable military packaging solution starts with asking the right questions.
During the intake, we want to understand what happens to the product throughout the entire logistics and operational chain. Of course, we look at dimensions, weight and vulnerability, but that is only the starting point.
How will the packaging be transported? Will it be stacked? How often will it be opened? Does one person need to be able to carry it? Will the equipment be used outdoors? Could it be exposed to dust, sand, moisture, large temperature fluctuations, shock or vibration? And are there specific standards, test requirements or other technical specifications set by the customer?
Ease of use is also part of the requirements as far as we are concerned.
This became clear, for example, when we developed a maintenance case for the F-16. The Royal Netherlands Air Force was not simply looking for a strong case for tools and spare parts. The case had to be compact and lightweight, resistant to impact and easy to clean. At the same time, technicians needed to be able to see quickly where each item belonged and whether the set was complete.
It is precisely these operational requirements that ultimately determine how the packaging should be designed.
Once the application is clear, we determine together which packaging solution is most suitable.
Fully custom-built packaging is not automatically necessary. In some cases, an existing case or enclosure is already a good fit, with the customisation mainly focused on the interior. In other situations, the construction, dimensions and functionality need to be developed entirely around the product.
And we look beyond protection alone.
A packaging solution can be technically very robust, but still fall short in practice if it is too heavy, difficult to open, takes up too much space or does not fit the user’s workflow.
The environment in which the equipment is deployed can also be decisive. For the Dutch Ministry of Defence’s TITAAN project, for example, Faes supplied enclosures for sensitive communication equipment. Protection against shock during transport was only part of the challenge. Dust, water and temperature also had to be taken into account. Different configurations therefore included protective racks, sealing and solutions for temperature control.
The packaging concept is therefore created from a combination of the product, the risks and the operational context.
Once the concept has been selected, our engineers translate the requirements into a technically feasible design.
This is where decisions are made about the construction, materials, fittings, cushioning, foam, internal fixation and accessibility of the product. Practical considerations such as carrying points, stackability, cleanability and the way the packaging opens can also form part of the design.
We do not work in isolated departments. Our advisers, engineers and production specialists stay in close contact throughout the project. This means manufacturability and production considerations can already be taken into account during the engineering phase.
For the F-16 maintenance kit, for example, this resulted in an interior in which every tool had a fixed position. By using different foam colours, users could immediately see when an item was missing. The design therefore solved more than just a transport challenge; it also supported the technician’s day-to-day work.
That is what customisation means to us: designing not only around the product, but also around the way it is used.
A design needs to be reviewed before it becomes final.
That is why we present concepts digitally and, where necessary, provide technical drawings for approval. The customer and other project stakeholders can review the design, provide feedback and approve decisions before we move forward.
Depending on the project, we can also use a prototype to assess aspects such as fit, layout, ergonomics or construction in practice.
Not every product, however, can simply be brought to Faes.
When we developed packaging for an F-16 vertical tail at Volkel Air Base, it could not simply be moved. Our engineer therefore travelled to the location to map the component and identify its vulnerable areas. Using 3D measurements, we were then able to create an accurate design. The packaging was ultimately assembled around the aircraft component on site.
A project like this shows why a fixed product range alone is not always enough. Sometimes the development process itself also needs to be adapted to the situation.
For defence applications, the question is not only whether a design looks robust. Where specific performance requirements apply, it may also be necessary to demonstrate that the packaging meets them.
That is why we consider verification and testing as early as the requirements phase.
Which loads are relevant to this application? Which properties need to be demonstrated? And which test method provides the right evidence?
This may involve shock or vibration testing, for example, but also tests focused on environmental influences. Where a project specifies requirements based on a particular standard, these are translated into concrete design and test conditions.
We therefore do not test simply because military packaging is expected to be “tested”. A test should answer a clearly defined technical question.
The outcome may confirm that the design meets the requirements, but it may also show that an adjustment is needed. In that case, our engineers use the results to further optimise the design.
Requirements, engineering and verification therefore form one integrated process.
Once the design has been reviewed, any required verification has been completed and the solution has been approved, we move into production.
Our production specialists translate the agreed specifications into the final packaging solution, from the enclosure and fittings to a fully customised interior. Because engineering and production work closely together, the original requirements can be monitored throughout the entire process.
Our involvement does not necessarily end at delivery.
Military equipment and applications change over time. Configurations can be modified, components can change and packaging may require maintenance after extended use. In these situations, we can provide support with repairs, modifications and further development.
From a compact F-16 maintenance case to protected ICT enclosures for TITAAN and custom packaging built around an F-16 vertical tail on site: the solutions can be very different.
The approach behind them is not.
We define the application and requirements, select the right concept, engineer the solution, make design choices reviewable and, where necessary, verify that the agreed requirements are met. Only then do we move into final production.
Because for us, military packaging should do more than simply be strong. It should demonstrably fit the equipment, the logistics chain and the people who work with it.
Do you have a defence product or system that requires a packaging solution? Our packaging experts are happy to get involved from the requirements phase onwards.
Michel Prins is Account Manager at Faes and a specialist in Safety & Security. Thanks to his background at the Ministry of Defense and years of experience in the sector, he advises organizations on reliable packaging solutions for critical applications. He combines practical knowledge with technical expertise to package sensitive equipment safely and efficiently.
More articles by Michel PrinsGood packaging doesn’t just happen by chance. Using a tried-and-tested approach, our specialists guide you step by step from the initial idea to the finished product.
