Every SYSMAX flashlight is constructed from light weight, high strength aero-grade aluminium alloy. Additionally, the majority of SYSMAX models are CNC machined from a solid aluminium bar. This manufacturing process gives NITECORE flashlights their superior shock/impact resistance, with many lights able to withstand being rolled over by car or dropped from several meters onto a hard surface with no performance loss (not recommended as may void warranty).

Compared to cheaper and weaker tubular aluminium flashlights produced by the majority of flashlight manufacturers today, SYSMAX offers significant gains in both ruggedness and performance. Furthermore, all SYSMAX models are treated with a military-spec type III hard anodized finish, making the flashlight surface as tough as diamond, thus protecting it from scratches, abrasions and corrosion.