I pack mine in the soft case that I put in the hard case. When TSA opens the hard case, there is a zipped soft case. They unzipped it and that seems to satisfy their need to check thing out. No problems thus far.
Go step-by-step in the book, one step at a time. Remain calm and think if it as a meditative practice.
I also tape a nice note to TSA on the inside of the case top explaining that this us a folding bike and I include photos of the folded bike in the case.
