Custom Insert for the Defibtech Lifeline AED
An automated external defibrillator (AED) is a device that lets a bystander help save a life during cardiac arrest. For it to work when it matters most, it needs to be perfectly protected, logically organised, and ready for immediate use.
The client came with a specific brief: develop a transport solution for the Defibtech Lifeline AED that protects the device and all accessories without increasing the overall dimensions of the case.
The challenge: A two-kilogram device with zero margin for error
The Defibtech Lifeline is a tested device with a drop resistance of 1.2 metres. Even so, operators needed confidence that it would handle rough conditions during transport, alongside a spare battery that must always be within reach.
Key requirements:
- Secure storage of the 2 kg device with no movement inside the case.
- Space for a spare battery without increasing the overall footprint.
- Immediate access in an emergency, with no extra steps.
- Materials suitable for medical environments (non-absorbent, easy to clean).
HaCase solution: Every centimetre with a clear purpose
We selected a hardcase from TBA PLAST and designed a custom insert that uses every cubic centimetre of the interior as efficiently as possible.
Trocellen XPE 33 foam
The insert was CNC-milled from Trocellen XPE 33 foam. The material has a closed-cell structure, which means it does not absorb moisture and is simple to wipe down. In the medical segment, those are not optional features.
Vertical layering
We split the entire interior into three functional layers:
- The main bed is milled precisely to the shape of the defibrillator. The device sits without any play.
- Below it sits a dedicated cutout for the spare battery. It stays with the device at all times, does not interfere with handling, and takes up no additional space.
- The case lid is lined with foam that gently presses the AED against the insert when closed. This eliminates any movement inside, even under significant impact.
Hardcase built for repeated use
The outer case is stackable, secured by two solid plastic latches, and fitted with a robust handle for quick retrieval. For hospitals or emergency services managing multiple units, that makes a practical difference.
Result
The device is secure, everything has its place, and in an emergency the case is ready to open and use without hesitation. That is the standard a life-saving device demands.
Case at a glance
- TBA PLAST hardcase with foam-lined lid to eliminate device movement.
- Trocellen XPE 33 insert, CNC-milled to measure.
- Hidden spare battery compartment beneath the device.
- Stackable case suitable for multi-unit storage.
- Materials suitable for medical environments.
