Firearm Packaging Solution

Our team at Forest City Companies offers a wide range of experience in developing packaging solutions for firearms and military hardware. We were asked by a firearms manufacturer to develop a foam and case solution that could survive extensive handling and drop testing. Their previous packaging design resulted in damage to their rifles due to a lack of stabilization. Their previous crating allowed the guns barrel to pierce through the protective foam and become exposed, causing severe damage during handling.

Using a sample rifle, we designed a foam and plastic case set with overall part dimensions of 55″ x 12″ x 6″; featuring tolerances as tight as + 1/8″. Our engineering team chose a highly dense polyethylene foam that was precisely die cut to touch and hold the rifle along its entire geometry. This would stabilize the rifle and prevent it from dislodging in the event of impact or excessive motion. It was an innovative foam design developed by our engineers. In addition, the foam material was inserted into a hardened plastic rifle case for an added layer of protection. All of our work was performed according to both our own standards and our customer’s ordinance quality guidelines.

In conjunction with our customer, we performed a series of drop tests that verified our design’s ability to keep the rifle stable. The tests were a complete success, protecting the rifle from movement while keeping it shielded from impact damage. From initial concept to final testing, our sales, engineering, and production staff worked with the customer to create a viable design that would provide better protection for their product. They were impressed by our results and we continue to manufacture rifle cases for them today. To learn more about our custom foam and case solutions, please contact us or refer to the table below.

Firearm Packaging Solution Highlights

Project Name & Description

Design and mfg die cut foam and case packaging solution for rifle

Capabilities Applied / Processes

Engineering design and mfg

Equipment Used to Manufacture Part

Die cutting, drop tests

Overall Part Dimensions

55 x 12 x 6

Tightest Tolerances

± 1/8″

Material Used

Polyethylene foam and plastic cases

Industry for Use


In Process Testing / Inspection Performed

FCP and Customers quality manual


1pc-26pcs at a time

Delivery / Turnaround Time

2 weeks

Delivery Location

Customer warehouse