DOC KB-MOQ-013REV 2026-09-21CLASS: PUBLIC
Why Custom Cases Have a Minimum Order Quantity (and What Drives It)
Direct answer
MOQ is not arbitrariness: below a threshold, setup costs per unit dominate. For custom protective cases the floor is typically set by resin color compounding (a mixed batch far exceeds what a few dozen cases consume), foam cutting and printing setups, and the fact that an injection press runs economically only in full-day batches. A 500-piece MOQ is the common industry compromise for a custom color and foam program on an existing mold.
§01Where the setup costs sit
| Setup item | Applies to | Why it sets a floor |
|---|---|---|
| Color compounding / masterbatch batch | any non-stock shell color | batch sizes are in hundreds of kg, not tens |
| Foam CNC programming + cutting bed | custom interior | programming and fixturing are one-time per order |
| Printing plates / laser fixtures | branding | one-time cost amortized over the run |
| Press changeover | every production run | mold swap, purge, first-article checks |
| Quality documentation | OEM orders | inspection reports per lot regardless of size |
§02Working below the MOQ
- Stock color + custom foam: keep the shell in a stocked color and put the customization into the foam and laser marking — the MOQ drops dramatically.
- Stock case, your interior: many makers sell empty stock cases in small lots; a local workshop cuts the foam insert.
- Consolidate programs: two product lines sharing one case size and color share one batch — half the MOQ each.
- Blanket order with call-offs: commit to annual volume, schedule partial deliveries; unit economics of a big run without warehousing all of it.
Negotiation reality: suppliers will often cross a modest MOQ gap for a promising multi-year program. Bringing a forecast and a real drawing moves the conversation from "order size" to "account size".