Foam welding allows us to join foam components quickly and securely, creating strong, permanent bonds without the need for adhesives or curing time. By using advanced techniques such as heat welding and hot-air welding, we produce clean, solid foam assemblies with precise joints and consistent structural integrity. This process ensures high accuracy and repeatability, making it particularly suitable for applications where reliability and durability are essential. Foam welding is especially well suited for mass production, as it provides consistent quality at high speed while minimizing material waste. The result is robust, long-lasting foam solutions that meet demanding functional and industrial requirements, supporting both standard and custom packaging applications with precision and efficiency.
Fast foam welding delivers clear advantages over traditional joining methods such as adhesive bonding. By eliminating the need for glue application and curing time, the process significantly accelerates production and enables higher output within shorter lead times. The result is a clean, controlled joining method that improves process efficiency while maintaining consistent quality. In addition to increased speed, foam welding produces strong, permanent bonds without introducing contaminants or residues, making it ideal for applications where cleanliness and precision are critical. The efficient use of material and reduced processing steps also contribute to lower waste and improved repeatability, supporting both high-volume production and demanding technical applications.
Welded seams are exceptionally clean and precise, resulting in a superior finish that enhances both the visual appearance and functional performance of the final component. The controlled welding process creates uniform joints with tight tolerances, contributing to a consistent and professional-quality result across all parts. Because the bond is formed within the foam material itself rather than through an external adhesive layer, the joints achieve significantly higher strength and long-term structural reliability. This internal bonding method eliminates weak points and reduces the risk of separation, delamination, or degradation over time. As a result, welded foam components maintain their integrity even when exposed to mechanical stress, frequent handling, vibration, or prolonged use in demanding environments.
At K-TEG, we combine CNC machining, waterjet cutting, knife cutting, and saw cutting to deliver comprehensive solutions for foam conversion and aluminium panel processing. This multi-technology approach allows us to select the most effective cutting method for each application, ensuring optimal accuracy, efficiency, and material performance. By utilizing a broad range of cutting technologies, we achieve precise results across varying materials, densities, and thicknesses—from soft foams to rigid panels and structural components. This flexibility enables us to produce reliable, reusable packaging components with tight tolerances and consistent quality, fully tailored to customer-specific requirements. Whether for standard production or complex custom designs, our cutting capabilities support high repeatability, clean finishes, and efficient manufacturing workflows.
Our cutting capabilities cover the full spectrum of foam and panel processing, enabling us to support both standard and highly customized packaging solutions. By combining CNC machining, waterjet cutting, knife cutting, and saw cutting, K-TEG ensures consistent tolerances, high dimensional accuracy, and repeatable quality across all production volumes. This integrated approach provides exceptional flexibility in design and allows us to efficiently process a wide variety of materials, densities, and thicknesses used in reusable packaging systems. As a result, we are able to deliver precisely engineered components that meet functional, durability, and performance requirements across diverse applications and industries.
For our customers, this versatility translates directly into improved packaging performance and long-term value. Aluminium, wooden panels, and other structural components are cut to exact dimensions, providing strength, durability, and a precise fit within the overall packaging system. At the same time, precision-shaped foam inserts ensure products are securely cushioned, well protected against impact and vibration, and easy to handle during packing, transport, and deployment.
Our splitting and lamination capabilities allow us to prepare foam materials with a high level of precision and versatility, enabling tailored solutions for a wide range of applications. By accurately controlling thicknesses and bonding multiple layers, we can combine different foam densities, material types, and colours within a single solution to achieve the desired balance of cushioning, strength, and durability. This flexibility allows us to engineer foam components with optimized performance characteristics, such as enhanced shock absorption, structural support, or long-term resilience. The ability to integrate multiple materials and visual colour differentiation also supports functional organization and product identification within reusable packaging systems. The result is consistent quality, reliable protection, and foam solutions precisely matched to both technical and practical requirements.
Foam splitting enables us to process foam blocks into sheets with highly consistent and precisely controlled thicknesses, ensuring the exact material profile required for each individual project. This level of accuracy is essential for producing custom foam inlays that fit perfectly within cases and reusable packaging systems, eliminating gaps and ensuring uniform support. By maintaining tight tolerances across all layers, foam splitting supports repeatable quality, reliable protection, and a professional finish. The result is foam components that integrate seamlessly with structural case elements, enhancing both the performance and durability of the complete packaging solution.
Lamination allows us to bond multiple foam layers into a single, integrated component, combining different densities, colours, and material properties to meet specific performance requirements. This layered approach makes it possible to engineer foam solutions that deliver the optimal balance of cushioning, rigidity, and long-term durability. By carefully selecting and combining materials, we create foam components that provide targeted protection where it is needed most, while maintaining structural support and ease of handling. The result is versatile, high-performance foam parts that enhance the functionality, reliability, and lifespan of reusable packaging systems.
Printing and laser engraving transform standard cases and foam components into professional, functional, and highly durable packaging solutions. Whether branding a Peli™ case or custom flightcase, or laser engraving foam inserts for clear identification and organization, we ensure precision and consistency in every detail. High-quality printing enhances brand visibility and long-term recognition, while laser engraving provides permanent, wear-resistant markings that remain legible even after intensive use. Engraved foam layouts support efficient workflows by clearly indicating tool positions, equipment orientation, and missing items at a glance. Together, printing and engraving add value beyond protection by improving usability, professionalism, and operational efficiency across reusable packaging systems.
We offer high-quality printing and laser engraving directly on flightcases and Peli™ cases, delivering permanent and professional markings such as logos, identification labels, serial numbers, and technical information. These markings are designed to withstand intensive handling and repeated use, ensuring long-lasting legibility and a consistent professional appearance throughout the product lifecycle.
Custom-printed flightcases and Peli™ cases make reusable packaging instantly identifiable while reinforcing brand visibility and a professional appearance. Laser-engraved foam inserts further enhance organization by clearly indicating equipment locations, enabling users to quickly locate and correctly replace items. This structured approach reduces handling errors, minimizes the risk of damage or loss, and supports efficient workflows in demanding operational environments.
Using advanced technology such as a portable 3D scanner, we capture even the most complex geometries and transform them into precise digital models ready for conversion. 3D scanning brings unmatched accuracy and flexibility to packaging design. By adjusting thicknesses and bonding layers, we create foam solutions that are tailored to performance, protection, and durability in reusable packaging systems.
This technology eliminates guesswork by capturing exact geometries, significantly reducing design cycles and minimizing the need for revisions or physical prototypes. Even irregular or highly complex shapes are replicated with exceptional accuracy, ensuring a precise fit within foam inserts, cases, and packaging systems. The result is faster development, improved consistency, and packaging solutions that deliver reliable protection and professional quality from the first iteration.
With K-TEG’s scanning expertise, clients benefit from packaging solutions that are highly accurate, efficiently developed, and precisely matched to their products. This approach ensures reliable performance and a professional fit, even for the most demanding and technically complex applications.
Testing and certification are integral parts of our packaging development process. From initial design through to final production, we ensure that each solution can be validated against the toughest defence, aerospace, and transport requirements, delivering proven performance in real-world operational conditions. Our packaging systems can be tested and certified in accordance with the most widely used standards in defence, aerospace, and logistics. Testing may include shock, vibration, drop, stacking, and environmental exposure, carried out by accredited laboratories and supported by comprehensive test reports. This structured approach provides assurance that every solution meets applicable performance, compliance, and reliability requirements
Certified packaging delivers confidence, operational efficiency, and global acceptance across demanding industries and supply chains. By validating performance against recognized international standards, certified packaging ensures predictable protection, simplified approvals, and compatibility with defence, aerospace, and logistics requirements worldwide. Our solutions can be tested and certified in accordance with ATA 300 Category I and II for reusable transport cases, MIL-STD-810 for environmental resistance, DEF STAN 81-41 for military packaging, and STANAG 4280, the NATO standard for reusable protective cases. In addition, ISTA procedures are used to verify performance during global transit and distribution. Together, these certifications provide documented assurance that packaging systems can withstand mechanical stress, environmental exposure, and repeated handling.
Meeting these internationally recognized standards simplifies procurement and approval processes while reducing technical risk across the supply chain. Clients gain confidence knowing their packaging solutions are thoroughly tested, independently verified, and widely accepted by defence, aerospace, and logistics organizations. This assurance provides peace of mind that every solution is trusted, compliant, and fully ready for worldwide deployment in demanding operational environments.
We can equip our packaging systems with integrated sensor technology, enabling customers to monitor critical conditions during transport and storage. In partnership with a trusted technology provider, we deliver intelligent packaging solutions that combine robust physical protection with real-time data on parameters such as shock, vibration, temperature, and humidity. This added layer of insight allows users to verify handling conditions, identify potential risks, and support quality assurance and compliance requirements throughout the supply chain. When combined with packaging systems that are tested and certified in line with widely recognized standards in defence, aerospace, and logistics, sensor integration provides full visibility and confidence
Through our collaboration with a specialized technology partner, we integrate advanced sensor solutions directly into cases and packaging systems. These sensors monitor key parameters such as temperature, humidity, vibration, impact, and location, providing continuous insight throughout transport and storage. This digital layer of oversight complements the physical protection of the packaging, enabling improved traceability, condition verification, and informed decision-making across the supply chain.
Sensor integration provides transparency and peace of mind. Sensitive equipment can be monitored from dispatch to delivery, ensuring that any deviation from acceptable transport conditions is immediately recorded. This reduces risk, supports compliance in regulated industries, and improves accountability across the supply chain. In defense, aerospace, broadcast, and industrial markets, it means valuable assets are not only well protected but also fully traceable.
K-TEG goes beyond physical packaging by enabling digital passport integration within cases and reusable packaging systems. In partnership with a trusted technology provider, we equip packaging with digital identification technologies such as RFID and barcode solutions, allowing essential data to be stored, accessed, and updated throughout the entire lifecycle of the asset. This digital passport can include product information, configuration details, maintenance history, inspection records, and usage data, supporting full traceability and control across logistics and operations. When combined with packaging systems that are tested and certified in line with widely recognized standards in defence, aerospace, and logistics, RFID- and barcode-enabled packaging provides a seamless connection between physical protection and verified digital data—enhancing compliance, accountability, and lifecycle management.
Combined with our precision foam conversion and durable case construction, this capability ensures that every packaging unit is not only fully functional but also digitally connected. By linking robust physical protection with secure digital data, we deliver smarter, traceable, and future-ready packaging systems. This integrated approach supports improved asset visibility, lifecycle management, and operational control across demanding applications and industries.
By making packaging easier to reuse, refurbish, and recycle at end of life, this technology helps reduce environmental impact and supports more accurate reporting on sustainability metrics. Digital identification enables better tracking of usage cycles, refurbishment activities, and material recovery, contributing to a more transparent and circular approach to reusable packaging. In defence, aerospace, broadcast, and industrial sectors, this capability delivers not only reliable asset tracking but also greater accountability for environmental performance. With K-TEG, clients benefit from packaging solutions that combine robust protection with long-term reusability—designed to support operational demands today while contributing to a more responsible and sustainable future.
Lithium-ion batteries are classified as dangerous goods and require packaging solutions that comply with strict international transport and safety regulations. At K-TEG, we design, manufacture, and certify battery packaging systems in accordance with UN 3480 and UN 3481, covering both standalone lithium-ion batteries and batteries contained in or packed with equipment. Our solutions are engineered to ensure safe transport, handling, and storage by mitigating risks such as impact, short circuit, thermal exposure, and mechanical damage. Using robust case construction, precision foam interiors, and compliant labelling and documentation, we support air, road, rail, and sea transport requirements. Each packaging system is developed with safety, regulatory compliance, and operational practicality in mind, providing customers with confidence that lithium-ion batteries are protected and fully compliant throughout the supply chain.
For air transport, our packaging solutions are designed to comply fully with the IATA Dangerous Goods Regulations, ensuring safe and approved shipment of lithium-ion batteries by air. For road transport, we adhere to ADR regulations, guaranteeing legal compliance, safety, and acceptance across European transport networks. By addressing the specific requirements of each transport mode, we provide packaging solutions that support secure, compliant, and efficient battery logistics from origin to destination.
Our packaging solutions are validated for thermal resistance, vibration, impact, short-circuit prevention, and containment, effectively mitigating risks throughout the entire logistics chain. Each system is designed to control movement, absorb energy, and prevent damage under demanding transport conditions. By combining advanced foam conversion, robust panel construction, and certified testing against applicable regulations and standards, K-TEG delivers lithium-ion battery packaging solutions that are safe, compliant, and fully prepared for global transport across multiple modes.
