BVM Pelicase PC Design, Manufacturing & Project Delivery

BVM Pelicase PC Design & Manufacturing Process

BVM designs and manufactures bespoke Pelicase-based industrial PCs to deliver rugged, portable, and highly reliable computing solutions for demanding operational environments. These systems are engineered for field deployment, mobile operations, industrial control, test and measurement, defence, utilities, broadcast, and remote data acquisition applications where conventional desktop or rack-mounted PCs are unsuitable.

By combining genuine Pelican protective cases with carefully selected industrial-grade components, BVM controls the entire design and manufacturing process in-house. This ensures long-term availability, mechanical robustness, predictable lead times, and full traceability from enquiry through to shipment and ongoing support.

End-to-End Design & Manufacturing Process

Requirements Capture & Project Initiation

Every Pelicase PC project begins with a structured requirements and discovery phase. This stage is critical to ensuring the final system is fit for purpose and performs reliably throughout its operational life.

Key Activities

Receipt of customer enquiry via website, email, or direct sales contact
Initial technical discussion to understand:
- Application and workload requirements
- Operating environment (temperature, dust, moisture, vibration)
- Portability and transport considerations
- Performance expectations and lifecycle requirements
- I/O, networking, and connectivity needs
- Compliance, certification, or industry standards
Review of customer specifications, drawings, or deployment constraints

Outputs

High-level requirements summary
Initial feasibility assessment
Internal project reference and ownership

Pelicase Selection & Mechanical Concept Design

BVM exclusively uses genuine Pelican cases due to their proven impact resistance, ingress protection, and global availability. Case selection is driven by both physical and operational requirements.

Design Considerations

External dimensions and weight limits
Internal usable volume and lid/base depth
IP rating and sealing requirements
Transport method (hand carry, vehicle, air freight)
Accessibility for service and upgrades

Mechanical Design Process

Internal layout planning and spatial optimisation
Orientation of motherboard, PSU, and storage devices
Design of custom CNC-cut aluminium mounting plates
Shock and vibration mitigation planning
Cable routing and strain relief design

Component Selection & Electrical Design

All components are selected for reliability, thermal stability, and long-term availability, rather than consumer-grade cost optimisation, ensuring consistent performance, predictable lifecycle support, and suitability for continuous operation in demanding industrial and field-deployed environments.

Core Components

Industrial or embedded motherboard (Mini-ITX, Micro-ATX, SBC)
Processor platform (Intel® Core™, Xeon®, Atom®, or embedded SoC)
Industrial memory (DDR4 / DDR5, ECC where required)
Industrial SSD storage (SATA or NVMe)
Power supply:
- Wide-input DC or AC
- Surge and transient protection

Electrical Design Activities

Power budget and load calculations
Grounding and EMI strategy
Thermal envelope validation
Internal cabling specification

I/O Planning & Panel Engineering

BVM Pelicase PCs are defined by clean, robust, and serviceable external connectivity.

I/O Design Process

Identification of all external interfaces:
- USB, Ethernet, serial (RS232/422/485)
- Video (HDMI, DisplayPort, VGA)
- GPIO, fieldbus, or customer-specific interfaces
Selection of connector types:
- Standard connectors
- Locking or ruggedised connectors

Panel Engineering

Precision machining of Pelicase panels
Integration of bulkhead connectors or waterproof glands
Port labelling and orientation checks
Seal and ingress protection verification

Thermal Management Strategy

Due to the enclosed nature of Pelicase systems, thermal design is a critical engineering stage.

Thermal Design Steps

Identification of heat-generating components
Passive versus active cooling assessment
Airflow modelling and internal layout refinement
Selection of:
- Fanless conduction cooling
- Filtered airflow solutions
- Temperature-controlled internal fans

System Assembly

All Pelicase PCs are assembled by trained engineers following documented build procedures.

Assembly Stages

Case preparation and inspection
Installation of mounting plates and standoffs
Motherboard and CPU installation
Memory and storage installation
PSU installation and wiring
I/O cabling and panel connections
Cooling solution installation
Final mechanical securing and inspection

Software Installation & Configuration

Systems are delivered ready for deployment, with software configured to match the application.

Software Activities

BIOS configuration and optimisation
Operating system installation
Driver installation and validation
Power management configuration
Optional customer application pre-load

Testing, Burn-In & Quality Assurance

Every Pelicase PC undergoes a structured testing and validation process prior to shipment.

Testing Stages

Initial power-on and functional test
Full I/O verification
Burn-in testing (24–72 hours)
Thermal stability monitoring
Final engineering sign-off

Documentation, Traceability & Lifecycle Control

Each system is supplied with full documentation and traceability.

Included Documentation

System specification sheet
Internal build and test records
Serial number traceability
BIOS and OS configuration summary

Lifecycle management includes:

Component change control
Revision tracking
Obsolescence management
Upgrade and refresh planning

Why Choose BVM for Pelicase PCs

Complete in-house design and manufacturing control
Industrial-grade components with long-term availability
Bespoke mechanical and I/O design
Proven testing and QA processes
UK-based engineering and support

BVM Pelicase PC Case Studies

Example Project Timeline: From Enquiry to Shipment

Stage 1 – Enquiry Received
- Week 0
  - Eenquiry received
  - Enquiry logged and acknowledged
  - Initial sales and engineering ownership assigned

Stage 2 – Requirements Discovery
- Weeks 0–1
  - Technical consultation with customer
  - Detailed discussion covering:
    - Application and workload
    - Environmental and operating conditions
    - Performance expectations
    - I/O, networking, and connectivity requirements
    - Compliance or certification needs
  - Review of customer documentation or specifications
Outcome:
- Requirements formally defined
- Project approved to enter design phase

Stage 3 – Design, Engineering & Delivery Phase
- Weeks 1–12 (12-week design and build process)
  - This phase represents the core BVM Pelicase PC design and manufacturing lifecycle.
- Weeks 1–3 – Concept & System Architecture
  - Pelicase model selection
  - Platform and component selection
  - Preliminary mechanical layout
  - Initial thermal and power assessment
- Weeks 4–6 – Detailed Engineering & Procurement
  - Final mechanical and I/O design
  - CAD drawings and panel layouts
  - Final bill of materials (BOM) approval
  - Ordering of Pelicase, electronics, and connectors
- Weeks 7–8 – Case Preparation & Mechanical Work
  - Case inspection and preparation
  - Panel machining and connector integration
  - Seal and ingress protection verification
- Weeks 9–10 – System Assembly & Software Configuration
  - Full system assembly
  - BIOS configuration and optimisation
  - Operating system and driver installation
  - Optional customer software pre-load
- Weeks 11–12 – Testing, QA & Shipment
  - Functional testing and I/O verification
  - 24–72 hour burn-in testing
  - Final inspection and documentation
  - Packaging and dispatch to customer

Contact BVM Today

If you are looking for a rugged, portable, and fully bespoke Pelicase PC designed for real-world industrial use, speak to BVM today. Our engineering team will work with you from initial concept through to delivery, ensuring your system is built exactly to your requirements and supported throughout its lifecycle. Contact BVM to discuss your Pelicase PC project or request a tailored quotation.

Example Configurations

The following designs and configurations showcase examples of solutions we’ve created for our customers and will hopefully provide you with an idea of what we can produce.

Ready to Discuss Your Project?

Contact BVM for all your Industrial and Embedded Computing OEM/ODM design, manufacturing or distribution needs. With over 35 years of experience, we supply standard hardware and design custom solutions tailored to your requirements.

Reach our expert sales team on 01489 780144 or email us at sales@bvmltd.co.uk.