Threw in "penny factor" for reference... (b/c not everybody carries a caliper and scale in their back pocket
Penny thickness: 3.5mm
Penny weight: 0.1oz
Phone weighs 4.6oz naked.
- Aegis is a little wider towards the top where the buttons are - 79.50mm
- Corner protection - Aegis is thicker and is all rubber; Tough Case is thinner and a combination of plastic over rubber. The Aegis design relies on the thick rubber corners to absorb the shock whereas the Tough case relies on the shell distributing the load on the thinner rubber. Hard to tell which is better for corner drops (which is usually how/when screens are most likely to shatter - load concentrated over a small area) without some destructive testing. I can say that I've dropped the phone several time on hard warehouse floors from chest height with the Aegis with no issues.
- Overall Protection - IMO, the Aegis provides a better overall protection due to the thicker rubber (at the corners as well as overall), hard case wrapping over the top and bottom (unlike the Tough Case) and port protection.
- Screen protection ("lift") on the Tough Case is slighter higher.
- Tough Case is much easier to get in and out of pocket.
- Buttons on the Tough Case are flush; On the Aegis, the buttons protrude a little causing accidental power-ons.
Was using Aegis as my daily but am switching to Tough Case due to smaller size, lighter weight and ease of getting in and out of the pocket. Will keep Aegis for the weekend outdoor excursions. Both are quality cases.