Portability and durability for defence and national security deployments

Reliable IT hardware is vital in modern defence and national security/intelligence operations. From a defence perspective, IT hardware may be employed in harsh battlefield environments or onboard naval vessels. From a national security and intelligence perspective, agents may transport classified data on commercial aircraft. These environments are subject to shock, vibration, and water ingress. In these scenarios, providing the integrity of critical IT infrastructure is vital, and rugged cases can help protect servers, switches, and other devices. Michael Crumpler, VP of engineering and product management at Ultralife Corporation, explains that case design is key and can influence field performance.

In defence and national security deployments, any equipment must withstand intense vibrations during transport, sudden shocks from accidental drops, and exposure to water and dust in open or hostile terrains. Standard IT hardware is not constructed to withstand this stress, so robust protective measures are necessary.

Rugged cases can help by incorporating advanced shock and vibration-dampening systems, and feature waterproof and dustproof seals that protect sensitive components, maintaining operational reliability regardless of the environment. Protection from water and dust ingress is key and can help the case become IP65-67 rated and other Mil-Std 810 environmental qualifications.

There are also logistical and operational constraints. Tactical deployments require quick and reliable transport of IT equipment, often in high-stakes situations. Rugged cases offer practicality, including integrated handles and wheels for rapid portability. These features allow defence and security personnel to carry and deploy heavy cases with minimal effort, so the mission can proceed without delays.

As defence and national security operations increasingly depend on real-time data processing and secure commissions, IT hardware has become more important. There is increasing demand for edge computing solutions — deployable IT hardware that processes data locally, without reliance on remote servers or satellite connections. This shift has allowed faster decision-making, enhanced data security, and delivered greater control over mission-critical systems, particularly in remote or contested areas.

Adapting IT hardware for the field has brought its challenges. Servers and switches, for example, are suited to data centres and may not have the necessary structural integrity to weather, vibrations, or harsh temperatures. However, providing the design is appropriate, these cases can ensure such devices are field-ready. Custom mounting brackets, blade retention systems, and shock-absorbing features are just some solutions that can help COTS equipment comply with stringent defence standards.

Durability is one of the main considerations when designing mobile cases and enclosures, such as the company's EL8000-MCS. Aluminium is a common material choice because it is lightweight yet robust. Unlike plastics, which can crack or degrade under extreme conditions, it can also withstand impacts and be formed back into shape. As well as extending the case's lifespan and reducing repair costs, it minimises waste – a key consideration in the drive towards sustainability.

As previously mentioned, shock and vibration dampening are also important. Cases such as the EL8000-MCS feature a suspended internal frame that absorbs impacts and vibrations during transportation. Consequently, the user can be confident that the hardware will function normally, even after enduring the severities of the field.

Although the cases must be durable and rugged, they must be easy to move around. Integrated handles on the front and rear of the case allow a two-person lift, distributing weight evenly while minimising strain on the handlers. Handles at the front and back of the case are particularly invaluable onboard vessels where there is insufficient room for two people and a case side-by-side. In some cases, wheels are added onto the rear, allowing users to roll the case over short distances without lifting it.

With the EL8000-MCS, the company has also made accommodations for lid storage. In field operations, the end user can often misplace the lid, which leads to unnecessary delays and equipment exposure. To prevent this, its case comes with two 2" interchangeable lids and quarter-turn latches, which can replace mismatched rack-mount lids and knuckle-busting latches. It might seem like a small detail, but it can make a huge difference in protecting and deploying IT hardware.

Regarding national security agents transporting confidential information by air, the company has designed a carry-aboard case (the EL8000-CA) that meets airline-compliant sizing requirements and can fit into the overhead space or under the seat of some aircraft. An integrated telescoping pull handle and roller-bearing wheels help users transport the case through the airport terminal like a suitcase.

For defence applications, the case design must comply with stringent defence requirements, particularly those that relate to reducing EMI that could compromise the IT hardware or other nearby electronic devices. Electrical bonding is crucial here, adding as many bonding points in the case as needed to meet defence Standard 461 (MIL-STD-461) – the defence's standard for EMI interference.

Security and advanced locking mechanisms can also help prevent unauthorised access to the IT hardware inside the cases. For example, government-approved padlocks can be combined with wire latches, safeguarding against tampering. Designing this level of security into the case is crucial, particularly for servers that contain sensitive or confidential data critical to national security.

Rugged cases are not just protective enclosures, they are tailored solutions designed to meet the needs of specific IT hardware and applications. The company has designed and installed blade retention brackets and custom mounting hardware for our cases to help secure our customers' servers and other IT components, even during intense shocks, vibrations, and movements. Usually, mounting hardware is unique to each customer, so a tailored solution is required. There is no industry standard for mounting, and servers are unique to each manufacturer, so we approach this on a case-by-case basis.

If a custom solution is needed, it is important to work with a partner that can support the entire integration process. For example, the company sells cases directly, but can also receive the customer's hardware and integrate it into a custom solution before shipping it back to their facility.

Rugged cases help protect IT hardware and prepare it for defence and field deployments. They combine durability, portability, and a tailored design, transforming standard equipment into mission-critical solutions. Whether for defence or another high-stakes application, a well-designed rugged case can help keep its contents secure and functional.