Welding parameters — power, electrode pressure and dwell time — are set and recorded for each incoming fabric batch, and a first-article sample is destructively peel-tested at the start of every production run. Curved welds at the buttstock radius are peel-tested as a separate section. Parameter records are available for OEM quality files.
Weldability depends on molecular polarity. TPU and PVC weld cleanly; polyethylene and polypropylene are non-polar and cannot be RF welded; uncoated nylon or polyester requires a weldable laminate. The 840D woven base carries abrasion resistance and the TPU laminate provides both the waterproof barrier and the weldable layer.
One-piece welded shell showing the chambered profile and welded pocket
A cylindrical dry bag is a straight seam repeated. A chambered gun case is not.
| Feature | Welding Consequence |
| Rounded buttstock chamber | Curved weld path; electrode tooling shaped to the radius |
| Tapered barrel chamber | Weld width must stay constant as the panel narrows |
| Flat 8 cm profile | Two large faces meeting at a narrow edge weld rather than a rolled tube |
| Welded accessory pocket | A second weld operation onto an already welded face |
| Zipper welded into the seam | Dissimilar materials joined in the same operation |
| Strap anchor patches | Hybrid welding at point-load positions |
Each of those is a separate tooling and parameter decision. It is why a chambered HF-Welded Gun Case carries higher development cost than a tube and why we quote tooling explicitly rather than folding it into a unit price.
Frequency is fixed by the equipment. Everything an operator can get wrong sits in three settings, established for each incoming fabric batch and recorded.
| Variable | Function | If Set Too Low | If Set Too High |
| Power | Rate of heat generation in the joint | Under-fused; seam separates cleanly | Material burns or thins at the weld |
| Electrode pressure | Forces softened layers together | Incomplete fusion across the weld width | Material displaced; weld thins |
| Dwell time | Total energy into the joint | Cold weld with poor bond strength | Overheating and embrittlement |
Cooling under pressure is the fourth step and the one most often skipped in low-cost production. Releasing the electrode before the fused polymer re-solidifies leaves a joint that looks correct and peels apart under load.
The process depends on molecular polarity. A polymer with a dipole responds to the alternating field and heats internally; a non-polar polymer does not respond at all, whatever power is applied.
| Material | RF Weldable | Note |
| TPU | Yes | Strongly polar; welds cleanly — the SL-E603 shell |
| PVC | Yes | Strongly polar; welds well, lower cost, heavier |
| PU coated | Varies | Depends on coating formulation and thickness |
| Polyethylene | No | Non-polar; needs hot-air or ultrasonic methods |
| Polypropylene | No | Non-polar; not RF weldable |
| Uncoated nylon or polyester | No | Base fabric alone cannot be welded |
This is why the shell is specified as TPU-laminated rather than as a woven fabric. The 840D woven base carries abrasion resistance; the TPU laminate is both the waterproof barrier and the layer that makes welding possible.
| Destructive peel test:on a correctly welded sample the parent fabric tears before the weld separates. A seam that opens cleanly along the weld line indicates insufficient energy into the joint and triggers a parameter review before production continues. This runs at the start of every production run, and the records are available for OEM quality files. |
| Failure Mode on a Stitched Case | On a Welded Shell |
| Seam tape lifts after heat and wash cycles | No tape present |
| Needle perforations reopen as adhesive ages | No perforations exist |
| Stitching works loose under vibration | No stitching in the waterproof body |
| Pocket seam leaks after being sewn through the shell | Pocket welded onto a continuous face |
| Strap anchors pierce the barrier | Anchors welded to reinforcement patches |
| Aggressive cleaning lifts a tape edge | Shell can be scrubbed and hosed |
| Item | Specification |
| Model | SL-E603 |
| Product type | Fully welded waterproof rifle case |
| Size | 122 × 30 × 8 cm (estimated) |
| Weight | approx. 1.1 kg (estimated) |
| Internal capacity | approx. 25–30 L |
| Shell material | 840D TPU laminated fabric |
| Construction | RF welded, one-piece body |
| Seam type | High-frequency welded, heat-sealed edges |
| Waterproof rating | IPX7 |
| Closure | Waterproof zipper |
| Accessory pocket | 1 welded waterproof zippered pocket |
| Profile | Rounded buttstock chamber, tapered barrel chamber |
| Carry | Adjustable removable shoulder strap + reinforced handle |
| Colourways | Khaki / Black / Army Green, two-tone |
| Firearm compatibility | Hunting, bolt-action, tactical rifles; shotguns |
| MOQ | 300 pcs |
| Sample lead time | 7–10 days |
| Production lead time | 30–45 days |
| OEM / ODM | Supported |
| Origin | China |
| Option | Notes |
| Custom body length | New electrode tooling developed as required |
| Chamber profile | Buttstock radius and barrel taper adjustable |
| Shell material | 840D TPU standard; 500D PVC tarpaulin alternative |
| PVC-free specification | TPU construction throughout |
| Welded logo patch | Applied without piercing the shell |
| Pocket configuration | Size, position, or a second welded pocket |
| Colour split | Two-tone welded panels in any combination |
| Parameter documentation | Welding records supplied for quality files |
1. Incoming fabric inspection and weldability trial on the batch
2. Welding parameter setup — power, pressure, dwell recorded per batch
3. First-article weld sample and destructive peel test
4. Precision cutting of panels to the chambered development
5. RF welding of the buttstock chamber radius
6. RF welding of the tapered barrel chamber and edge seams
7. Welded attachment of the accessory pocket and zipper seam
8. Hybrid welding of strap anchors and handle mounts
9. Immersion verification against the IPX7 condition
10. Final inspection and export packing
| Check | Method | Frequency |
| Material weldability | Trial weld on incoming batch | Every batch |
| Parameter record | Power, pressure, dwell logged | Every batch |
| First-article peel | Destructive peel on a sample weld | Start of every run |
| Weld appearance and edge definition | Visual, in process | Continuous |
| Weld width consistency | Measured against approved sample | Sampling |
| Curved-section weld | Visual at the buttstock radius | 100% |
| Finished water integrity | Immersion check | Per approved sampling plan |
| Trial | Method | Outcome |
| Seam peel | Destructive peel on a welded sample | Parent fabric tore before seam separation |
| Curved weld integrity | Peel test at the buttstock radius specifically | Held equally to straight-section welds |
| IPX7 immersion | Sealed case immersed to 1 m for 30 minutes | No ingress at any welded seam |
| Seam flex fatigue | Repeated flexing at the weld line | No cracking or separation |
| Hydrolysis resistance | Extended warm humid exposure | No seam softening or delamination |
| Low-temperature integrity | Flexed after 12 hours at -20 °C | Seams intact; no brittle fracture |
| Scrub and hose | Repeated aggressive cleaning of seam areas | No degradation; no tape edge to lift |
| Anchor patch pull | Sustained load at welded strap patches | No separation of the welded patch |
High-frequency welding is capital equipment rather than a subcontracted operation. Our welding lines run in-house at Dongguan, China and Ho Chi Minh City, Vietnam, electrode tooling is developed in-house for custom shapes, weldability is trialled on every incoming batch, and the welding line and inspection process are open to buyer audit.
The brand wanted a deeper buttstock chamber for guns with adjustable combs, which changed the weld radius rather than just a dimension. We developed new electrode tooling for the revised curve and peel-tested the curved section specifically before approval, since a curved weld is where tooling error shows first. 450 pcs, 47 days including tooling.
Their compliance team required welding parameter records per batch alongside the immersion report, having previously accepted a supplier's verbal assurance. We supplied logged power, pressure, and dwell figures with the shipment and the first-article peel results. 600 pcs, 43 days.
Market requirements ruled out PVC entirely. The standard 840D TPU construction was already compliant, and we confirmed material composition documentation through the supply chain rather than substituting anything. 350 pcs, 42 days.
“Curved welds are where a supplier gets found out. You tested that section on its own and showed us the result.”
— Product Engineer, Hunting Brand
“Parameter records per batch turned a claim into a document. Our compliance team stopped asking questions after that.”
— Quality Manager, Importer
“If the fabric tears before the seam, there is nothing left to argue about. That was the test that convinced us.”
— Sourcing Lead, Outdoor Equipment Distributor
An electromagnetic field at 27.12 MHz reverses polarity roughly 27 million times a second. Polar molecules in the TPU attempt to realign with each reversal, and the internal friction generates heat through the full thickness of the joint at once. Under electrode pressure the softened layers fuse and re-solidify as one continuous section.
A tube is a straight seam repeated. This shell has a curved buttstock chamber requiring tooling shaped to the radius, a tapered barrel chamber where weld width must stay constant as the panel narrows, a welded pocket applied to an already welded face, and a zipper welded into the seam. Each is a separate tooling and parameter decision.
Destructive peel testing. On a correct weld the parent fabric tears before the seam separates. A clean separation along the weld line means insufficient energy and triggers a parameter review before production continues.
Power, electrode pressure, and dwell time, set per incoming fabric batch and recorded. Cooling under pressure is the fourth step and the one most often skipped in low-cost production — releasing the electrode early leaves a joint that looks correct and peels apart under load.
No. The process needs molecular polarity. TPU and PVC weld well; polyethylene and polypropylene are non-polar and cannot be RF welded at all. Uncoated nylon or polyester requires a weldable laminate. Weldability is trialled on every incoming batch.
Yes, on our own lines at Dongguan, China and Ho Chi Minh City, Vietnam, with electrode tooling developed in-house. The welding line and inspection process are open to buyer audit.
Seam tape lifting, needle perforations reopening as adhesive ages, stitching working loose under vibration, pocket seams leaking where sewn through the shell, and strap anchors piercing the barrier. None of those failure modes exist on a welded shell.
Yes. With no seam tape to lift, welded seams tolerate cleaning that would damage a taped case — useful after salt, silt, or blood exposure.
No. After twelve hours at -20 °C the seams remained intact and flexible with no brittle fracture at the weld line.
Yes. The standard 840D TPU construction is PVC-free, and material composition documentation can be supplied through the supply chain for markets requiring it.
Yes. Electrode tooling is developed in-house for custom lengths, chamber profiles, welded reinforcement, and logo patches. Tooling is quoted explicitly rather than folded into the unit price.
MOQ 300 pcs, samples in 7–10 days, production in 30–45 days, quoted EXW, FOB, or CIF, with tooling development quoted per project and welding parameter documentation available for quality files.
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No. 88, Fenggang Section of Dongshen Road, Fenggang Town, Dongguan City, Guangdong Province, China
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