Gemstar Manufacturing

Gemstar Manufacturing is a U.S.-based manufacturer of military-grade protective hard cases and custom plastic components for demanding UAV and unmanned systems applications.

With over six decades of experience, the company continually pushes the limits of plastic manufacturing to provide rugged solutions that can withstand the rigors of transportation and the most extreme field environments. Gemstar’s protective cases are trusted across a wide range of mission-critical defense and aerospace applications, providing rugged protection for sensitive equipment during transport, storage and field deployment.

Gemstar is ISO 9001:2015 certified and ITAR registered, and can develop and test products to a wide range of standards including MIL-STD-810, IP67 under IEC 60529, ASTM transport and handling standards, and STANAG 4280/AEPP-3.

Military-Grade Protective Hard Cases

Stronghold® Rotationally Molded Cases

Double-walled waterproof protection for demanding transport and storage requirements

Stronghold® cases are heavy-duty, long-life reusable containers designed to house mission-critical equipment in challenging environments. Manufactured from GSR high-performance resin, the rotationally molded cases combine double-walled construction with airtight and watertight sealing to ensure the utmost protection. The case line is designed and tested to meet or exceed MIL-STD-810G and military long-life reusable container requirements.

Interlocking stackability allows cases to be securely arranged for storage and transportation. Recessed hardware provides additional protection, and rubberized spring-loaded handles allow convenient handling. Other features include patented latches and a gasketed tongue-and-groove closure.

Available in more than 100 sizes and configurations, Stronghold® cases can be thoroughly customized inside and out to match the dimensions and protection requirements of a wide variety of drone airframes, robotic systems and supporting equipment.

Learn more: Stronghold® Rotationally Molded Cases

RoboRack® Half Rack Cases

Configurable rack-mounted protection for sensitive electronics

RoboRack® half rack cases provide rugged protection for sensitive electronic components in a configurable, portable format. Manufactured using Gemstar’s precision Robomold® technology and GSR high-performance resin, they offer double-walled construction and airtight, watertight sealing for the protection of critical UxV payloads, sensors and equipment.

The half rack case line is available in 3U, 5U, 7U and 9U sizes, with configurable options to meet different equipment requirements. Fully removable lids can be hung on the sides of the case, and edge wheels and an extendable pull handle ensure easy mobility. An interlocking design allows cases to be stacked securely.

RoboRack® cases are designed and tested to meet or exceed MIL-STD-810F and military long-life reusable container requirements.

Learn more: RoboRack® Half Rack Cases

Sentinel® Injection Molded Cases

Lightweight protective cases for portable equipment

Sentinel® cases combine lightweight, single-walled construction with GSI impact-resistant resin to provide durable protection solutions that are ideal for a wide range of small UAS and supporting equipment.

The injection molded case range is available in more than 20 sizes, with interior and exterior customization options for specific equipment configurations.

Watertight protection is provided by a gasketed tongue-and-groove closure incorporating an EPDM gasket. Standard features include pressure relief valves, stainless steel hardware, molded-in padlock brackets and secure, easy-open latches.

Sentinel® cases are designed and tested to meet or exceed MIL-STD-810F and military long-life reusable container requirements. Custom colors and additional hardware options allow the finished case to be tailored to specific customer requirements.

Learn more: Sentinel® Injection Molded Cases

Case Customization & Engineered Packaging Solutions

Gemstar can tailor its cases to provide custom protective solutions for drones and UAS, with a wide range of options to meet specific protection, configuration and handling requirements. In addition to protecting airframes and payloads, these cases can also form integrated housings for ground control stations and test equipment, offering durable and weather-resistant enclosures for field use.

Custom routing and cutouts allow cases to be adapted to specific configurations, and foam interior options include closed-cell and anti-static. Thermoformed plastic inserts, panel mounts, elastomeric isolator mounts and wire-rope isolator mounts provide further options for securing and protecting equipment. A wide variety of environmental protection measures can also be incorporated, including EMI shielding, pressure relief valves, humidity indicators, electronic humidity sensors and desiccant holders.

Custom Plastic Parts Design & Manufacturing

Gemstar offers precision component design and manufacturing services tailored to the needs of UAS and unmanned systems OEMs. The company’s expert team of in-house designers and engineers work closely with customers throughout the entire development process, providing a wide range of services including R&D consultation, 3D rapid prototyping, material composition and sourcing.

These fully custom-engineered solutions serve commercial and defense applications alike, and are designed to meet your exacting requirements with unparalleled precision and repeatability at scale.

Gemstar’s production expertise includes: