2026-09-21 · KeXinMaterials Editorial Team

DJI Drone Case B2B Wholesale Guide: Mavic 3 / Matrice 30 / Phantom 4 Pro / Air 3 Foam Inserts

DJI drone cases are the highest-volume protective case category in B2B wholesale. A DJI Mavic 3 Pro + 3 batteries + controller + charger needs 28-35L internal volume. DJI Matrice 30 (M30) needs 60-90L due to payload capacity. B&W sells pre-cut foam for Type 1000/3000/6000. Pelican and Nanuk sell DJI-specific molded cases (945 DJI Mavic 3, 965 DJI M30). KeXinMaterials (box-beeaa.com) offers custom CNC-cut foam for any DJI model, 148 SKUs across 9 lines, IP67/IP68, 30-45 day production, FOB Shenzhen/Ningbo. Below is the 2026 B2B wholesale guide covering internal volume requirements per DJI model, foam density selection, IP rating requirements, battery transport compliance (UN 38.3), and custom foam design workflow.

DJI Model Internal Volume Requirements

Every DJI model has a different footprint. Foam insert must match drone body + gimbal + controller + batteries + charger + ND filter set. Below are verified internal volume requirements per model.

DJI Mavic 3 Pro: folded 245 x 118 x 134 mm. With 3 batteries (each 233 x 74 x 70 mm folded) + RC Pro controller + ND filter set. Required internal volume: 32-38 L. Recommended case: 400 x 350 x 250 mm internal (36 L).

DJI Mavic 3 Classic: folded 245 x 118 x 134 mm (same chassis as Pro). Same volume requirement: 32-38 L.

DJI Air 3: folded 171 x 101 x 165 mm. With 2 batteries + RC 2 controller. Required internal volume: 22-26 L. Recommended case: 330 x 280 x 200 mm internal (18.5 L) with 2-layer foam.

DJI Phantom 4 Pro: 350 x 350 x 180 mm with props. Required internal volume: 42-50 L. Recommended case: 475 x 350 x 200 mm internal (33.3 L) — matches B&W Type 6000 footprint.

DJI Matrice 30 (M30): 470 x 585 x 215 mm with props (largest consumer/pro DJI). Required internal volume: 85-120 L. Recommended case: 620 x 520 x 350 mm internal. Nanuk 965 holds 119.7 L — the industry benchmark.

DJI Matrice 30T (thermal): same chassis as M30 with thermal payload. Same 85-120 L requirement.

DJI Mini 4 Pro: 165 x 100 x 70 mm folded. Required internal volume: 12-16 L. Recommended case: 250 x 200 x 150 mm internal (7.5 L) with single-layer foam.

DJI Inspire 3: 820 x 620 x 620 mm (full cinema gimbal). Required internal volume: 200-280 L. Two-case solution typical (body case + gimbal case).

Common packing list per drone: 1x drone body, 2-4x intelligent flight batteries, 1x remote controller (+ 1x RC Pro for Pro models), 1x charger, 1x power adapter, 4-8x propeller pairs, 1x ND filter set (Pro models), 1x gimbal protector, 1x shoulder bag.

B2B relevance: Correct internal volume is the #1 procurement mistake. Under-sizing forces buyer to remove batteries from the case (violates UN 38.3 shipping requirement). Over-sizing wastes freight cost. Volume calculation must include 15-20% foam allowance.

Foam Density + Cut Type Selection

Closed-cell polyethylene (PE) foam is standard for drone cases. Density 25-35 lb/ft3 for structural protection, 15-20 lb/ft3 for delicate gimbal. Pick-and-pluck vs CNC-cut vs layered.

PE closed-cell foam (cross-linked polyethylene): standard for drone cases. Density 25-35 lb/ft3 (0.42-0.59 g/cm3) provides structural protection against 1-2m drops. Water-resistant (IP67 compatible). Non-toxic.

PU (polyurethane) foam: density 15-20 lb/ft3 for gimbal + camera protection. Softer cushioning for delicate sensors. Open-cell (absorbs water — NOT suitable for waterproof cases).

EVA foam: density 30-45 lb/ft3. Lightweight + shock absorbing. Common in low-cost cases. Less durable than PE.

Pick-and-pluck (P&P) foam: user cuts layers to fit. Cheap + flexible. Downside: irregular cuts reduce protection precision. Best for low-MOQ prototypes (10-50 units).

CNC-cut / laser-cut foam: precision cutouts for exact drone + accessory footprint. Higher tooling cost (USD 200-500 per design) but best protection. Best for 100+ MOQ production runs.

Layered / stepped foam: 2-3 layers of different density. Top layer (lid) softer for gimbal, bottom layer denser for batteries + body. Best practice for M30 + Phantom 4 Pro.

EVA + PE hybrid: PE structural shell + EVA cushioning layer. Best for high-value cinema drones (Inspire 3).

Foam thickness: 25-30 mm for 15-20 lb/ft3 PU. 40-50 mm for 25-35 lb/ft3 PE. Total foam layer consumes internal volume — must be accounted for in case sizing.

Flame retardancy: PE foam typically FMVSS 302 / CA TB 117 compliant. Requirement for airline cabin carry-on (ATA 300 Cat I).

B2B recommendation: For 100+ MOQ, CNC-cut PE foam (density 30 lb/ft3) with layered PU lid insert. Provides best protection per unit cost. For 10-50 MOQ prototype, pick-and-pluck PE.

IP67 / IP68 + Waterproof Case Requirements

Drone cases for field operations (surveying + inspection + agriculture) must be IP67 minimum. Coastal + marine applications need IP68. KeXinMaterials offers both.

IP67 (IEC 60529): dust-tight (6) + temporary immersion 1m for 30 min (7). Standard for outdoor survey + inspection drone cases. Salt spray + rain + dust resistant.

IP68: dust-tight (6) + continuous immersion per manufacturer spec (8), typically 3m for 2+ hours. Required for marine survey + underwater ROV operations + coastal drone deployment.

KeXinMaterials IP67 + IP68 cases: O-ring sealed + automatic pressure equalization valve. EPDM gasket. Operating temp -40 to +120°C.

Pressure equalization valve critical for drones: aircraft cargo hold pressure differential can crack seals + implode cases. Both KeXinMaterials + Pelican + Nanuk + SKB include automatic valves.

Battery condensation: LiPo batteries outgassing during storage. Case must include desiccant packet + vent valve that allows gas out but not water in. KeXinMaterials includes desiccant bag option.

Salt spray (ASTM B117): coastal operations. 96h+ salt fog exposure tested cases recommended. KeXinMaterials project-specific testing available.

UV exposure: outdoor drone cases exposed to direct sun for 200+ hours. Material must be UV-stable. PP + ABS blend standard. Avoid PVC (chalking + cracking under UV).

B2B recommendation: For survey + inspection + agriculture, IP67 + EPDM gasket + pressure valve + desiccant. For marine + coastal, IP68 + stainless steel hardware + salt fog tested.

UN 38.3 Battery Transport + ATA 300 Air Travel

LiPo batteries are the #1 constraint in drone case design. UN 38.3 governs air transport. ATA 300 Category I governs airline check-in acceptance.

UN 38.3 (UN Recommendations on the Transport of Dangerous Goods, Section 38.3): governs lithium battery transport. Tests T1-T8: altitude simulation, thermal cycling, vibration, shock, external short circuit, impact, overcharge, forced discharge.

UN 38.3 case design requirement: case must prevent (1) short circuit via battery terminal contact, (2) impact damage, (3) thermal runaway propagation, (4) water ingress. Non-conductive interior + terminal protection + impact-resistant shell + ventilation.

IATA DGR (Dangerous Goods Regulations): air transport of lithium batteries. Drone case with 2-4x LiPo batteries typically exceeds 100 Wh total — requires "state of charge restriction" (30% SOC for air transport since 2016 IATA rules).

IATA 30% SOC rule: for air transport, LiPo batteries must be at 30% charge or less (since Jan 2017 for passenger aircraft). Drone case design should include a documented SOC discharge procedure card.

ATA 300 Category I: airline check-in acceptance standard for photographic + electronic equipment cases. 100+ airlines accept ATA 300 cases. Requires (1) TSA-approved lock, (2) pressure equalization valve, (3) internal foam, (4) exterior dimensions within airline limits.

TSA-approved lock: Required for ATA 300 Cat I cases accepted by US TSA for airline check-in. TSA-approved lock models: TSA000 series. KeXinMaterials offers TSA lock option on request.

Cabin carry-on limit: Most airlines limit cabin baggage to 56 x 36 x 23 cm (22 x 14 x 9 in). DJI Mavic 3 case (400 x 350 x 250 mm) EXCEEDS cabin limit — must be checked. DJI Air 3 case (330 x 280 x 200 mm) FITS cabin limit. Important differentiator for buyer.

IATA lithium battery marking: Cases containing lithium batteries must display UN 3480 / UN 3481 labels depending on battery type (packed with equipment vs contained in equipment). Drone batteries shipped contained in drone = UN 3481.

B2B relevance: For B2B drone case procurement, buyer must verify (1) case prevents short circuit, (2) battery terminals protected, (3) documentation for IATA + UN 38.3 compliance, (4) ATA 300 Cat I for airline acceptance. KeXinMaterials provides UN 38.3 + IATA DGR compliant battery transport cases.

Custom Foam Design Workflow + B2B Pricing

Custom foam design workflow: buyer provides drone + accessory list, KeXinMaterials measures, CNC cuts, ships sample, buyer approves, production run. 7-15 days foam lead time, 30-45 days total production.

Step 1 — Specification: buyer provides DJI model + accessory list (drone body, battery count, controller type, charger, ND filters, prop count) + target case internal dimensions.

Step 2 — CAD / 3D scan: KeXinMaterials creates CNC foam cut path from buyer spec or 3D scan of physical drone. Standard layout: bottom layer holds drone body + batteries, lid layer holds controller + charger + ND filters + spare props.

Step 3 — Sample: KeXinMaterials produces 1-2 sample cases with custom foam (7-15 days). Buyer tests fit. Adjustments free within 2 rounds.

Step 4 — Approval + tooling: buyer signs off. CNC cutting path is finalized (no tooling cost for CNC laser / waterjet cutting).

Step 5 — Production: 30-45 days for 100+ MOQ. Includes case molding + foam CNC + assembly + QC.

Step 6 — QC: 100% fit check on first 10 units. AQL sampling per ISO 2859-1. Drop test verification per MIL-STD-810 reference.

B2B pricing (2026, FOB Shenzhen/Ningbo, 100+ MOQ): Standard IP67 case with pick-and-pluck foam USD 18-35/unit. IP67 case with CNC-cut layered foam USD 28-55/unit. IP68 stainless hardware case with CNC foam USD 45-85/unit. Wheeled variants (M30 + Inspire 3) add USD 12-25/unit.

MOQ: 100 units per model per foam design. Below 100, pick-and-pluck foam recommended (no CNC tooling).

Lead time breakdown: case molding 15-20 days + foam CNC 7-10 days + assembly + QC 5-8 days = 30-45 days total.

Payment: T/T 30% deposit + 70% before shipment. EXW Shenzhen / FOB Shenzhen / FOB Ningbo only (no DDP).

Brand compliance: KeXinMaterials (Guangdong) Co., Ltd. — source factory established 2014, 13,000 m2, 60+ machines, 20+ patents, 148 SKUs across 9 product lines. B2B export only, no retail.

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