Zippered two-shell EVA hard case with a die-cut foam insert in the base and elastic syringe retention in the lid. Sized for a three-day protocol: six 1 mL syringes, two 3 mL peptide vials, one 10 mL bacteriostatic-water vial, alcohol swabs, a capped sharps tube and a slim gel cold pack. Reference geometry is in the accompanying 3D file (GLB / OBJ).
| Item | Spec | Note |
|---|---|---|
| External, closed | 180 × 120 × 56 mm | Includes zipper track; excludes pull tab and carry loop |
| Base shell height | 36 mm | Outer, floor to rim |
| Lid shell height | 20 mm | Outer, floor to rim |
| Wall thickness | 4.0 mm | Molded EVA, uniform |
| Corner radius, plan | R16 mm | Outer; inner follows at R12 |
| Internal cavity | 172 × 112 mm | Base usable depth 32 mm; lid 16 mm |
| Open angle | 110° stop | Fabric spine limits lid; free-standing when open |
| Target weight, empty | ≤ 260 g | Insert and cold pack included |
| Part | Material | Finish / colour |
|---|---|---|
| Shells (2) | Compression-molded EVA, 4 mm, 1680D polyester outer laminate | Matte black, fine grain; no gloss |
| Interior lining | Brushed polyester tricot, bonded to shell | Charcoal |
| Foam insert | Closed-cell EVA, 24 mm, die-cut, Shore 35–40 A | Charcoal, matches lining |
| Elastic straps | Woven elastic 12 mm, 25 % stretch | Black, single orange stitch line PMS 1655 C along one edge |
| Mesh pockets (2) | Polyester diamond mesh with #3 coil zipper | Charcoal; orange pull tabs |
| Main zipper | #8 coil, two sliders, water-resistant tape | Black tape and teeth; orange webbing pull tabs |
| Cold pack | Non-toxic gel in TPU film, 160 × 100 × 6 mm | Slate blue; sits under insert, not user-facing |
| Sharps tube | PP, 25 mm Ø × 90 mm, screw cap, puncture-rated | White body; orange cap |
| Brand plate | Debossed rubber patch, 30 × 8 mm, on base front face | Orange PMS 1655 C |
Origin at the cavity centre, X across the width (right positive), Z along the depth (front positive). Cutouts are through the full 24 mm insert thickness; the insert sits on the cold pack, so cutout floors are the cold pack's TPU face.
| Cutout | Size | Centre (X, Z) | Holds |
|---|---|---|---|
| Vial trough 1 | 62 × 28, R8 | −54, −36 | 3 mL peptide vial, lying, crimp toward +X |
| Vial trough 2 | 62 × 28, R8 | −54, 0 | 3 mL peptide vial |
| Vial trough 3 | 62 × 28, R8 | −54, +36 | 10 mL bacteriostatic water vial |
| Sharps trough | 30 × 100, R13 | +4, 0 | Sharps tube, lying along Z |
| Pocket recess | 60 × 100, R6 | +54, 0 | Zip mesh pocket, 12 mm deep, swabs |
Retainer strap: one 14 mm elastic across the three vial troughs at X = −54, stitched into the lining at both walls, orange stitch line on top.
| Element | Size | Position | Note |
|---|---|---|---|
| Zip mesh pocket | 162 × 20 mm | Along the far edge (opposite hinge) | Prescription card, spare caps |
| Strap A | 162 × 12 mm | Z = −12 mm | Stitched at both walls, orange stitch line |
| Strap B | 162 × 12 mm | Z = +30 mm | Same construction |
| Syringe bays | 6 × Ø 10 mm | 25 mm pitch, X = −62.5 … +62.5 | 1 mL insulin syringes, capped, cap toward hinge; straps hold, no cut foam |
Shells compression-molded and lined; lining wraps the rim and is caught under the zipper tape. Zipper runs three sides; the fourth (hinge) side is a 6 mm fabric spine bonded to both shells and sized to stop the lid at 110°. Foam insert is a friction fit with a lift tab at +X so the cold pack can be swapped. Carry loop is a 28 mm webbing half-loop stitched into the base wall at the right end. No exposed metal on the interior.
| Check | Requirement |
|---|---|
| Drop | 1.2 m onto concrete, six faces, loaded with dummy glass vials: no shell crack, no vial contact damage |
| Thermal | Cold pack frozen 8 h; cavity ≤ 15 °C for 6 h at 25 °C ambient |
| Zipper | 5,000 cycles, no tooth loss or slider skip |
| Elastic | Retains a 9.5 mm syringe after 2,000 insert/remove cycles |
| Odour / VOC | Low-odour EVA; no off-gassing at 40 °C, 24 h |
Quotation at 500 / 1,000 / 3,000 units; tooling cost and lead time; one hand sample in the specified colourway; die-line drawing of the foam insert for approval before cutting. Reference 3D geometry is exported in metres, Y-up, part names as listed above.