Extreme Cases Limited
About us
Extreme Cases designs and manufactures lightweight, rugged aluminium containers, 19” racks and enclosures for demanding industrial environments.
Drawing on experience from defence and mission-critical programmes, we bring the same engineering discipline and build quality to industrial, manufacturing and laboratory applications where equipment protection really matters.
Our range includes IP66 aluminium cases, 19” rack systems for field and lab use, and custom case solutions for tools, instruments and equipment. We also offer precision-machined foam and Shadow Foam tool control, providing clear visual management and secure protection.
Additional options include environmental dataloggers, fan monitoring and internal mounting systems, helping customers protect, monitor and deploy equipment with confidence.
Exhibiting at Southern Manufacturing for the first time, we’re looking forward to meeting manufacturers and engineers seeking practical, well-engineered protection solutions.
👉 Visit our stand to meet the Extreme Cases team and discuss your application.
Designed and manufactured in the UK, we support projects from one-off prototypes to production volumes.
Products & services
Lockdown Aluminium Containers
Our Lockdown rugged aluminium containers deliver unmatched durability and protection. Offered in a range of standard sizes or as fully custom builds, they are available in military-standard (F>12) and industrial-standard (F>6). Unlike competitors’ containers—typically made from 1 mm aluminium and only weatherproof—we do not compromise: Lockdown containers start at 1.5 mm aluminium as standard and are all minimum IP66 rated. We also machine precision custom foam internals to securely protect sensitive equipment in transit and storage. Trusted by NATO, the UK MoD, and the Bundeswehr for critical equipment transport and storage.
Watertight Plastic Cases
We supply watertight cases from HPRC, Peli and SKB, engineered to protect equipment in extreme conditions. Add CNC-cut custom foam, integrated panels, and monitors for a complete solution. Perfect for defence, media, medical, and scientific applications where portability and total equipment protection are essential. Explore our full watertight range.
19" Racks and Enclosures
Protect sensitive electronics from shock and vibration with precision-engineered aluminium 19” racks. Tested to MIL-STD-810, they’re ideal for defence, SATCOM, and industrial use. Fully customisable with climate control, EMC shielding, system integration, and smart monitoring. Discover how Extreme Cases can build the right rack solution for you.
Custom Foam Packs
Designing and manufacturing the correct foam internals is a major part of the protective packaging solution as many customers need custom foam inserts! At our Base X facility in Barnstaple, we have recently installed a top-of-the-line Biesse Rover Plast A CNC machining centre. We can now create complex and tailor-made foam packs and gaskets for cases, containers, and drawers. - Equipped with 13 tool stations - Drag & oscillating knives - State of BSolid CAM software with 3D simultaneous machining capability Extreme's custom foams provide lightweight, durable, flame-retardant, static-dissipative protective packaging widely used in aerospace and defence to safeguard high-value components during transport.
Case Sentinel Datalogger
Discover the power of precise monitoring with our advanced, battery-powered data logging application, designed for continuous measurement of mechanical forces and environmental conditions. Housed in a compact, rugged enclosure measuring 120 × 95 × 25 mm, the device is IP66 splash-proof and engineered to perform reliably in demanding environments. It monitors shock, tilt, temperature, and humidity, withstanding operating and storage temperatures from –35°C to 85°C and shock levels up to 16g in any direction. An integral rechargeable battery ensures dependable long-term operation, while a status-check pushbutton and optional cable extensions provide flexible deployment options. The system connects to a PC via USB for full data access and control through dedicated software. Users can program sensor exceedance limits, configure routine logging intervals, and assign unique names to individual dataloggers. Logged data can be easily downloaded as CSV files, clearly identified by datalogger name for streamlined analysis and traceability. With robust performance, intuitive software, and customizable features, this solution delivers accurate, actionable insights for critical monitoring applications.