OSAAP Case Studies
Real-World Examples of Custom Foam and Transport Case Solutions
Case Study:
Microsurgical Specialties Transport Cases
About the Client:
Microsurgical Specialties supplies Synovis and Biover medical products to Australian and New Zealand surgeons performing microsurgical and reconstructive procedures. Their commitment goes beyond distribution: they partner with hospitals and surgeons to provide the right products, logistical support, clinical guidance, and educational services, ensuring better patient outcomes.
The Challenges
Microsurgical Specialties was experiencing ongoing issues with transporting delicate medical equipment. Previous cases were not designed for safe handling. Staff and clients were reporting the following issues:
- Tools and instruments were breaking due to movement inside cases.
- Cases were not waterproof, allowing water ingress during transit in wet conditions.
- Lack of handles or wheels meant cases had to be lifted manually, creating inefficiency and risk of injury.
- Cases could only be stored upright; tipping them caused equipment to shift or be damaged.
- Upon return from hospitals, staff had to manually check every item, which was extremely time-consuming.
- These challenges were costly, labour-intensive, and disruptive to hospital operations, with equipment damage delaying critical procedures.
The Solution
OSAAP Australia partnered closely with Microsurgical Specialties to create custom transport cases specifically engineered for delicate microsurgical equipment. The process began with the tools being brought into OSAAP for professional imaging. Using light panel technology, each instrument was photographed in detail to ensure every measurement and contour was captured accurately. These images were then imported into OSAAP’s Blue Shadow CAD software, where precision foam shadow boards were designed to hold each item securely in place.
Once the designs were complete, they were sent to Microsurgical Specialties for review and approval. After sign-off, the shadow boards were manufactured using advanced foam routing and laser cutting, with laser etching applied to provide permanent labels and branding. The foam was heat-sealed to ensure durability, and then carefully assembled into rugged Pelican cases equipped with wheels and handles for safe, efficient transport.
This comprehensive approach ensured that every tool had a designated spot within the case, preventing movement and breakage during transit while streamlining storage and handling. The result was a solution that combined safety, convenience, and long-term operational efficiency for both Microsurgical Specialties and the hospitals they serve.
The Result
The custom transport cases delivered immediate and long-term benefits for Microsurgical Specialties, improving safety, efficiency, and ease of use.
Immediate Benefits:
- Lighter cases with wheels and handles allow easy, safe movement by freight staff.
- Cases can be tipped for easier storage without risking damage to equipment.
- Each tool has a designated spot, preventing breakages during transport.
- Improved efficiency for logistics partners, including SmartWays Logistics.
Long-Term Gains:
- Upfront investment in cases and foam reduces future replacement costs.
- Quick visual checks of equipment save time and labour when returning sets.
- Case sizes and materials comply with hospital health and safety regulations.
- Professional, organised presentation enhances usability and operational workflow.
“We are incredibly happy with the finished products regarding the organisation of implants and instruments, the efficiency of checking the sets in and out, and the overall professional presentation.
Whilst we are very happy with the finished product, what is more important is our customers’ reaction.
They are very impressed with the product organisation, the lightweight cases, and the handles and wheels on the cases for easy transportation.”
Case Study:
CRIMP-TECH Australia Transport Cases
About the Client:
CRiMP-TECH Australia is a family‑owned specialist in high‑reliability electrical wiring tooling and associated products, proudly serving the aerospace, defence, rail, industrial, and renewable energy sectors. With over 35 years of experience, CRiMP‑TECH has built a strong reputation as a trusted supplier across the Asia‑Pacific region, offering precision tooling, calibration services, and technical support.
The Challenges
CRiMP-TECH needed a transport and storage solution that could protect high-value tooling while maintaining organisation and accountability throughout storage and transit. Their previous packaging solutions fell short: tools were not securely held in place, presentation was inconsistent, and there was a risk of damage during handling or transportation. The lack of an organised system also made it difficult to track and account for each item efficiently, potentially impacting operational workflows and customer satisfaction.
The Solution
OSAAP Australia worked with CRiMP-TECH to design a tailored solution that met their strict protection, organisation, and presentation requirements.
Each tool was scanned using precise imaging techniques and processed using our Blue Shadow CAD software to create a high-density shadow board using foam from Zotefoams, custom-fit to every instrument. Laser etching was applied to identify each tool clearly and ensure consistent placement.
The completed shadow board was housed in a rugged Pelican case, chosen for its durability, watertight properties, and ease of handling. This combination of high-density foam and protective casing created a system that kept all tools secure, visible, and immediately usable, whether in storage or during transit.
The Result
The completed solution delivered immediate improvements in presentation, protection, and accountability. Over time, CRiMP-TECH experienced reduced replacement costs, improved transport reliability, and greater operational efficiency when moving and handling critical tooling.
“At Crimp-Tech Australia, we only offer the highest quality tooling for aerospace and defence, and we demand the highest quality foam for our custom-made kits to protect our customers’ investments. This is why we use OSAAP Australia for their high-quality work to ensure that the end-user gets the highest possible protection for their tooling.”
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