Pelican Protector vs. Air vs. Vault: Which Case Series Is Best for Your Needs?

Key Takeaways

• Pelican Protector cases offer maximum durability with IP67 waterproofing for military, law enforcement, and harsh environments
  
• Pelican Air cases provide up to 40% weight reduction without sacrificing protection for photographers and frequent travelers
  
• Pelican Vault cases deliver solid protection at a budget-friendly price, though weather-resistant rather than fully waterproof
  
• All three benefit from custom foam inserts, but Protector and Air work best for precision multi-item layouts

If you've ever dropped expensive gear or traveled through rough conditions, you know not all cases are equal. Pelican has built its reputation on one promise: your stuff will survive. For over 40 years, they've been the go-to brand for everyone from military operators to professional photographers.

Pelican makes three distinct series, each built for different users. The Protector, Air, and Vault lines all carry the Pelican name, but they're not interchangeable. Choosing wrong means lugging extra weight or skimping on protection.

As an official Pelican dealer, Foamerica sees these cases in action daily. We handle them, customize them, and hear from customers about what works. This guide breaks down pelican case series differences so you can pick right.

Quick Comparison Table

Pelican Protector Series: The Original Industry Standard

What Makes Protector Cases Unique?

When people think "Pelican case," they picture the Protector series. This original design made the brand famous. You'll find these pelican protector cases in military operations, police vehicles, and professional film sets worldwide.

Protector uses thick-wall construction handling serious abuse. Cases get thrown from helicopters, submerged in water, and crushed under equipment without breaking. The specialized polypropylene copolymer absorbs impacts that crack lesser cases.

Key Features

• IP67 waterproof and dustproof rating: Gear stays dry when fully submerged
  
• Automatic pressure equalization valve: Prevents vacuum lock during flights
  
• Stainless steel hardware: Hinges and latches won't corrode
  
• Dense protective foam options: Multiple cushioning configurations

IP67 means the case sits in three feet of water for 30 minutes without leaks.

Best Use Cases

Based on Foamerica customer data, Protector cases suit:

• Firearms and tactical gear: Most common use
  
• Heavy equipment: Test instruments, medical devices, specialized tools
  
• Harsh environments: Military deployments, offshore work, extreme weather
  
• High-value fragile items: When failure isn't an option

Why Customers Choose Protector

A wildlife photographer told us his Protector case tumbled down a rocky Alaskan slope. The case was scratched, but his $15,000 camera and lenses inside? Perfect. Another ships sensitive calibration equipment internationally. After five years, his Protector cases still seal perfectly.

Industries buying from us include law enforcement, oil and gas companies, construction firms, and outdoor professionals.

Pelican Air Series: Lightweight Performance Without Compromise

The Technology Behind Pelican Air

Pelican addressed travelers and photographers who loved their cases but hated airport hauling. Could they make cases equally strong but lighter?

Enter Air series, built with proprietary HPX² resin. This reduces weight by up to 40% versus Protector while maintaining strength standards. If you've carried loaded camera cases through three connecting flights, you understand why this matters.

Key Features

• Lightest cases Pelican makes: Without sacrificing toughness
  
• IP67 waterproof rating: Same protection as Protector
  
• Ultra-durable latches and hinges: Redesigned for smooth operation
  
• Optional padded dividers or TrekPak: Flexible organization

Picking up an Air case first time reveals an immediately obvious weight difference.

Best Use Cases

The best pelican case for cameras is usually Air series. Buyers include:

• Drone operators: Multiple batteries and controllers add weight fast
  
• Camera gear: Professional equipment with frequent travel
  
• Travel photography: Carry-on compliance matters (like Air 1535)
  
• Field researchers: Scientists hiking to remote locations with instruments

Why Clients Choose Air

A documentary filmmaker ordered custom foam for three Air cases. Weight savings literally changed his workflow. Instead of checking bags risking damage, he carries everything aboard. Reduced weight meant less fatigue during 12-hour shoots.

Travel photographers appreciate models like the 1535 Air fitting overhead bins.

Pelican Vault Series: Affordable Protection for Everyday Use

Where Vault Fits in the Pelican Lineup

Not everyone needs military-grade protection or wants to pay for it. Vault series is Pelican's entry-level option, though "entry-level" still beats most competitors' premium cases.

Vault uses high-impact polymer instead of expensive materials in other series. You get solid protection at friendlier prices. Trade-off? Weather-resistant rather than fully waterproof.

Key Features

• High-impact polymer construction: Tough for most situations
  
• Rugged build at lower price: Usually 30-40% less than Protector
  
• Solid latching system: Secure closures, not fancy Press & Pull latches

Best Use Cases

Vault makes sense for:

• Recreational users: Weekend warriors, hobby enthusiasts
  
• Lighter-use firearm storage: Range trips, basic transportation
  
• Basic equipment transportation: Tools, electronics, sporting goods
  
• Home or hobby storage: Organization and protection

Who Should Choose Vault

In our experience working with tactical and photography professionals, Vault suits people stepping up from soft cases who don't need full waterproofing. If you're not dunking cases in rivers or dropping from vehicles, Vault delivers value.

Side-by-Side Feature Comparison

Weight and Portability

Protector cases are heaviest. A Protector 1650 weighs about 18 pounds empty. The equivalent Air 1605 weighs around 11 pounds. That seven-pound difference matters when carrying for hours or hitting airline limits.

Vault cases fall in the middle. For frequent travelers, weight settles the debate.

Durability and Protection Level

Ranked by ruggedness:

1. Protector: Maximum impact resistance, thickest walls, highest crush tolerance

2. Air: Close to Protector in testing, lighter material

3. Vault: Solid for normal use, lower extreme tolerance

Waterproof vs. Weather-Resistant Protection

Protector and Air carry IP67 ratings. That's a standardized international rating meaning complete protection against dust and water immersion up to one meter for 30 minutes. The IP rating system is used for military and marine equipment.

Vault cases are weather-resistant. They keep out rain and splashes, but aren't designed for submersion.

Foam and Customization Options

Protector and Air work beautifully with custom foam. Smooth interior walls and precise dimensions create exact-fit layouts. After handling hundreds of Pelican case builds, we can say these offer the best platform for complex designs.

Vault cases use foam inserts fine. For basic protection like single firearms or simple layouts, they work great. For precision multi-item loadouts needing perfect nesting, slightly less refined Vault interiors create small challenges.

Foamerica's custom foam process: Send STP or DXF files, or we trace items in-house. We CNC-cut foam with precision to fractions of a millimeter. Takes four to six weeks. Choose from PE, XLPE, PU, or Zote foam. We offer engraving and labeling so you know where each piece goes.

The right foam turns a protective case for equipment into professional transport. Custom foam inserts prevent shifting, crucial for expensive or delicate items.

Which Pelican Case Should You Choose?

For Photographers and Videographers

Best choice: Pelican Air

Photography hard case needs balance weight and protection. You're carrying expensive, fragile gear needing protection while moving constantly. Air strikes perfect balance. Weight savings make tangible difference during long shoots.

For Firearm Owners and Tactical Users

Best choice: Pelican Protector

Tactical cases need maximum impact resistance and complete waterproofing. Protector is built for this. Thick walls, stainless hardware, and IP67 rating mean firearms stay protected.

For Travelers and Frequent Flyers

Best choice: Pelican Air

The best pelican case for travel is Air series. Models like 1535, 1545, and 1605 are designed for airline travel. Lighter weight helps stay under baggage limits. Carry-on sizes mean keeping valuable gear with you.

A client flying 200+ days yearly switched from Protector to Air three years ago. The pelican travel case options in Air line make life easier constantly moving.

For Budget-Conscious Buyers

Best choice: Pelican Vault

If you need durable hard shell luggage but can't justify premium price, Vault delivers. You get Pelican reputation and quality without advanced features.

For Harsh Environments

Best choice: Pelican Protector

Rain, mud, sand, extreme heat or cold... if gear faces rough conditions regularly, Protector is the answer. IP67 rating and robust construction handle environmental challenges destroying lesser cases.

For Custom Foam Layouts

Best choice: Protector or Air

For precision organization of multiple items, these two are best. Smooth interior surfaces and exact dimensions make cutting custom foam easier. We create custom protective cases looking professional keeping everything exactly in place.

How Custom Foam Inserts Bring Out the Best in Any Pelican Case

Why Custom Foam Matters

Generic foam (pick-and-pluck style) works okay for single items. For multiple equipment pieces, generic foam has limitations. Items shift, surfaces rub together, space isn't used efficiently.

Custom foam eliminates that. Each item gets precisely cut cavity. Nothing moves during transport, essential for expensive equipment safety.

Foamerica's Expertise in Pelican Foam Inserts

We've cut custom foam for Pelican cases for years. Our process starts understanding what you need protected. CAD files (STP or DXF format) work directly. Otherwise, we trace items in-house creating perfect templates.

Cutting uses CNC precision, accurate to tiny fractions. We offer PE foam (economical, lightweight), XLPE foam (cross-linked durability), PU foam (premium cushioning), and Zote foam (softer touch for polished surfaces).

We add engraving to label cavities, making packing and inventory faster. Timeline is four to six weeks from approval to delivery.

Example Layouts

We've created layouts for amazing use cases. A nature photographer needed Protector 1650 for two camera bodies, six lenses, batteries, and accessories. Everything had its place. Foam kept delicate lens elements from touching anything during backcountry travel.

A tactical trainer ordered Air cases with foam for complete pistol training kits. Medical equipment companies use our custom foam in Protector cases shipping delicate diagnostic instruments.

Final Verdict: Choosing the Right Case Series

Which pelican case is best for you? Match case to actual needs:

Choose Protector for maximum durability, complete waterproofing, handling extra weight. Professional choice for serious protection.

Choose Air for frequent travel, lighter weight, full IP67 protection. Premium price gets premium materials and travel-friendly designs.

Choose Vault for solid protection at budget-friendly price without full waterproofing. Smart choice for less demanding applications.

No matter which series, consider adding custom foam maximizing potential. A Pelican case with precision foam becomes more than protection. It's a complete system for organizing, transporting, and accessing gear.

Ready to find the perfect case? Browse our Pelican cases or contact us about custom foam options.

Frequently Asked Questions

1. What's the main difference between Pelican Protector and Air cases?

The biggest difference is weight. Air cases use proprietary HPX² resin making them up to 40% lighter than Protector while maintaining same IP67 waterproof rating. Protector uses thicker polypropylene construction offering slightly higher impact resistance. If you travel frequently or carry gear long distances, Air makes sense. If your case travels by vehicle facing harsh environments, Protector is better.

2. Are Vault cases actually waterproof?

No, Vault cases are weather-resistant but not fully waterproof like Protector and Air. They keep out rain, splashes, and moisture, but aren't designed for submersion. If you need guaranteed waterproofing (IP67 rating), go with Protector or Air series.

3. Can I use custom foam with any Pelican case series?

Yes, all three work with custom foam inserts. However, Protector and Air have more precise interior dimensions and smoother walls, ideal for complex multi-item layouts. Vault works fine for simpler foam designs but can be slightly less precise for intricate cutouts.

4. Which Pelican case is best for airline travel?

Air series is specifically designed for travel, with models like 1535 Air and 1545 Air meeting most airline carry-on size requirements. Weight savings (up to 40% lighter) helps stay under baggage limits while maintaining full IP67 protection.

5. How do I decide between Protector and Air if I need maximum protection?

Both offer excellent protection with IP67 ratings. Choose Protector if your case faces extreme conditions (military deployments, harsh weather, heavy industrial use) or if weight isn't a concern. Choose Air if you need same protection but carry the case frequently or travel by air. Air series is surprisingly tough despite being lighter.