Pelican Products, Inc., a global leader in protective cases and rugged gear, identified an opportunity to modernize its custom foam editor to better align with evolving customer expectations. The legacy tool had served its purpose but lacked the intuitive design experience and advanced capabilities that today’s consumers value. To stay competitive, Pelican sought a solution that would deliver a seamless, interactive experience for designing custom foam inserts—enhancing personalization and supporting continued order growth.
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Customer Benefits
- Significant increase in daily revenue from foam orders
- Doubled annual revenue year-over-year (2022–2024)
- Expanded product offering from 75 to 102 case models
- Increased foam material options from 2 to 8 types
- Streamlined operations and reduced time-to-delivery
- Achieved 90% positive customer feedback
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Project Highlights
- Delivered an intuitive UI with real-time 3D previews
- Completed 3D preview functionality ahead of schedule
- Achieved seamless integration with Pelican’s backend systems
- Developed an admin panel for region-specific configurations
- Secured positive client feedback and high user satisfaction
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Why AMC Bridge?
- Software engineers with both functional and technical expertise, combined with deep understanding of 3D models, ensuring high-quality delivery with minimal rework
- Robust 3D visualization expertise that brings concepts to life and accelerates confident, data driven decisions
- Proven track record in developing CAD and web-based design tools
- Deep domain knowledge across manufacturing workflows
- Strong client references and trusted reputation for reliability
- Agile methodology ensuring flexibility and rapid iteration
Client
Pelican Products, Inc. is the global leader in high-performance protective cases, temperature-controlled packaging solutions, advanced portable lighting systems, and rugged gear. Their products serve professionals in demanding markets such as defense, aerospace, life sciences, and industrial sectors.
Challenges
Pelican Products offers a custom foam fabrication service that allows customers to design protective inserts tailored to their equipment. As customer expectations and digital design standards evolved, the previous web application for custom foam design no longer supported the level of usability and flexibility users were seeking. Feedback highlighted opportunities to expand customization options and improve interface intuitiveness, prompting Pelican to pursue a more modern, user-friendly solution.
The challenge was to deliver a modern, user-friendly platform that could handle complex design requirements, integrate with existing systems, and support global markets.
Solution
To address the challenges, Pelican Products partnered with AMC Bridge to develop a robust, web-based application that enables consumers to design custom foam inserts with real-time 3D previews, material selection, and seamless ordering. Key components included:
- 3D Visualization: Realistic previews with accurate textures for better decision-making.
- User Interface: Responsive design with dedicated pages for case selection, foam design, and checkout.
- Design Algorithms: Ensured precision and manufacturability of custom foam layouts.
- System Integration: Connected to Pelican’s backend for streamlined order processing.
- Admin Panel: Enabled region-specific configurations for global flexibility.
Beyond the initial scope, AMC Bridge introduced several strategic improvements:
- ‘Replace Case’ Functionality: Simplified switching to the most suitable case, improving flexibility and reducing friction in the design process.
- Case Color Selection: Added color options for personalization, aligning with user preferences and branding needs.
- Expanded Foam Material Support: Increased from two to eight materials with realistic 3D visualization and accurate textures for a more immersive experience.
- Support for Laser Engraving: Added capability to allow user to embed laser engraving using their custom artwork.
- Performance & SEO Optimization: Improved application speed, accessibility, and search engine visibility, driving higher traffic and engagement.
These enhancements were embraced by the client and proved instrumental in elevating the product’s functionality, user experience, and market competitiveness.
Process
The project involved complex design, integration, and market adaptation challenges, requiring close collaboration and innovative technical solutions. AMC Bridge delivered ahead of schedule on key features, including:
- Generating accurate scalable vector graphics from 3D models
- Ensuring foam design manufacturability
- Integrating with legacy order processing and manufacturing systems and third-party tools
- Supporting multiple geographical markets (US, EU, Canada, Australia)
To ensure rapid delivery and alignment with Pelican’s strategic goals, AMC Bridge followed an agile, phased approach:
- Discovery: Workshops and analysis to define requirements and roadmap
- Implementation: Delivered ahead of schedule, leveraging engineers’ combined functional and technical expertise for fast, high-quality execution with minimal rework
- Continuous Enhancement: Ongoing improvements, including new SKUs, colors, and usability upgrades
This collaborative process ensured transparency, flexibility, and consistent progress through regular demos and status updates, accelerating time-to-market while maintaining quality.
Results
The collaboration between AMC Bridge and Pelican Products delivered a high-performing, web-based solution that revitalized client’s custom foam service and positioned Pelican Foam as a leader in custom protective solutions.
By replacing the legacy foam editor with a modern, scalable platform, AMC Bridge transformed the service into a user-friendly experience, delivering measurable business impact:
- Doubled revenue over two years
- Expanded product and material offerings
- Increased customer satisfaction and usability ratings
- Improved operational efficiency through reduced manual effort
Shree Khare, Chief Information Officer of Pelican Products, highlighted the measurable value delivered by the initiative: “The incremental site enhancements—including the expansion of SKUs, color options, technical improvements and new capabilities—have driven meaningful and sustained results over the past year. This progress reflects disciplined execution, strong cross-functional collaboration, and a clear focus on delivering value to our customers. AMC provided excellent engineering talent and partnered closely with our teams to deliver high-quality outcomes. Excellent momentum.”
Consumers praised the intuitive design and ease of use:
- “Great system and ridiculously intuitive!”
- “Phenomenal ease of designing. Love it!”
- “Experience with the custom foam designer was awesome! Very easy to customize my custom foam shapes.”
- “As a marketing/designer professional, I thought the process was streamlined and very intuitive. Thank you.”
- “I love this tool!”
The success of the project stemmed from a strong partnership between Pelican Products and AMC Bridge, driven by AMC Bridge’s proactive approach, unwavering commitment to quality, and technical excellence, delivering a solution that provides tangible value to Pelican’s customers.
About Pelican Products
Pelican Products, Inc. is the global leader in high-performance protective cases, temperature-controlled packaging solutions, advanced portable lighting systems, and rugged gear. Their products serve professionals in demanding markets such as defense, aerospace, life sciences, and industrial sectors. Learn more at www.pelican.com.
About AMC Bridge
AMC Bridge is a global software development consultancy enabling digital transformation for clients in the engineering, manufacturing, and construction industries since 1999. AMC Bridge specializes in custom software solutions that connect complex systems, eliminate data silos, and unlock innovation. With deep expertise in CAD/CAM/CAE APIs, computational geometry, and 3D visualization, AMC Bridge helps clients accelerate development and achieve business-critical outcomes. Learn more at amcbridge.com.
