Protective Controller Case Design for Industrial Machinery

A £6,000 industrial controller was being damaged repeatedly due to drops. We designed a custom protective case with a lanyard attachment and magnetic mount, saving the client thousands in replacements while improving usability and workflow efficiency.

The Problem

Our client was using a £6,000 controller to operate a high-value industrial machine. Unfortunately, the controller was frequently dropped by staff during operation.
Each fall caused significant damage, leading to costly replacements, operational downtime, and growing frustration on the factory floor.

The Challenge

The controller manufacturer did not offer any protective housing or accessories, leaving the client with no off-the-shelf solution.
They needed a custom-designed protection system that would:

Prevent damage from accidental drops
Be practical and easy to use in a fast-paced environment
Integrate seamlessly into their existing workflow

Our Solution

We designed and produced a bespoke protective case that addressed all of the client’s needs:

Robust outer shell engineered to withstand heavy impacts
Integrated lanyard attachment to keep the controller securely worn around the neck
Built-in magnetic mount allowing it to attach directly to the machine when not in use

The design was intentionally simple, durable, and ergonomic — ensuring the protection didn’t come at the cost of usability.

Our Process

Research & Analysis – We assessed the controller’s design, dimensions, and weak points to identify where protection was most critical.
Concept Development – Several prototypes were 3D-modeled and reviewed with the client to ensure form, fit, and function.
Testing & Refinement – Drop tests and magnetic strength evaluations were performed to confirm durability and ease of use in real-world conditions.
Final Production – The final product combined strength, functionality, and user comfort into a single protective solution.

The Outcome

The protective case has already saved the client thousands in potential replacement costs and significantly reduced downtime.
Operators now handle the controller with confidence, and the built-in magnet ensures it’s always within reach — not on the floor.

Results at a Glance

💰 Thousands saved in replacement costs
⚙️ Reduced downtime and interruptions
👷 Improved usability and workflow

Let’s Work Together

If your equipment is costing you money every time it breaks, we can help design a custom protective solution that saves you time, frustration, and expense.
Let’s chat — you might be surprised how much you could save.