What wood is used for flight cases?

Professional flight cases predominantly use birch multiplex plywood with 7 to 9 cross-laminated layers. Standard thicknesses are 6 mm for lightweight applications, 9 mm for general touring cases, and 12 mm for heavy-duty transport. Birch multiplex offers superior screw-holding strength, impact resistance and dimensional stability compared to softwood alternatives. Phenolic resin coating on exterior surfaces enhances moisture resistance and surface durability. For weight-critical applications, honeycomb plastic panels such as Adam Hall SolidLite provide 40–50% weight savings while maintaining adequate rigidity, though with lower screw-holding capacity requiring more frequent hardware mounting points.

What type of foam is used in flight cases?

Flight case interior protection typically uses polyethylene foam or polyurethane foam in densities ranging from 25 kg/m³ to 80 kg/m³. Soft polyethylene foam (25–35 kg/m³ density) provides cushioning for lightweight, impact-sensitive equipment such as microphones or controllers. Firm polyurethane foam (50–60 kg/m³ density) offers structural support for heavier equipment such as amplifiers or lighting fixtures, preventing compression under load. Convoluted "egg-crate" foam increases contact surface area by approximately 300% compared to flat foam, distributing pressure more evenly. Custom-routed foam inserts created using hot-wire cutting or CNC routing provide precise equipment fitment and prevent movement during transport.

What thickness plywood for road case?

Standard road case construction uses 9 mm birch multiplex plywood for walls, lid and base panels, providing an optimal balance between strength, weight and cost. Lightweight cases for equipment under 10 kg total weight may use 6 mm plywood to reduce case weight. Heavy-duty applications – particularly cases for equipment exceeding 40 kg or cases subject to stacking loads – benefit from 12 mm plywood for the base panel, with 9 mm panels for walls and lid. For maximum strength in professional touring environments, a double-layer base construction using 6 mm plywood beneath the primary 9 mm base panel creates 15 mm total thickness, preventing base flexing and stress on corner joints.

What material are flight cases made of?

Professional flight cases combine multiple materials engineered for durability and protection. Structural panels use birch multiplex plywood (typically 9 mm thickness) or honeycomb plastic panels for lighter weight. Aluminium extrusion profiles (30 mm or 35 mm face height, 1.2–2.0 mm wall thickness) form the protective frame around case perimeters. Hardware components include nickel-plated steel butterfly latches, ball corners, recessed handles and piano hinges. Transport solutions use heavy-duty castors with load ratings from 80 kg to 350 kg per wheel. Interior protection relies on polyethylene or polyurethane foam in various densities. 19-inch rack integration uses steel rack rails with cage nuts and mounting screws. All materials are selected for strength-to-weight ratio and resistance to touring environment stresses.

Can I use case building materials to repair existing flight cases?

Case building materials are ideal for repairing existing flight cases, as most professional manufacturers use standardised components from suppliers such as Penn Elcom, Adam Hall and Riggatec. Common repairs include replacing worn butterfly latches (measure existing latch dimensions to ensure correct size match), installing new castors (verify mounting plate dimensions and load rating requirements), replacing damaged ball corners (note corner radius – typically 30 mm, 40 mm or 60 mm), and renewing worn handles. Panel repairs may require matching plywood thickness and species – birch multiplex is standard. Foam inserts can be replaced with custom-cut foam to accommodate equipment changes. Always use equivalent or higher-specification replacement components to maintain case structural integrity and load capacity.

Are the latches and hinges rust-proof?

Quality case hardware uses corrosion-resistant finishes to withstand humid touring environments and outdoor exposure. Butterfly latches manufactured from 0.8 mm steel receive protective coatings including zinc plating (basic corrosion resistance), chrome plating (enhanced durability and aesthetic finish), nickel plating (superior corrosion resistance) or black oxidising (corrosion protection with matte appearance). Stainless steel variants offer maximum corrosion resistance for marine environments or permanent outdoor installations, though at higher cost. Piano hinges typically use zinc-plated or nickel-plated steel; continuous stainless steel hinges are available for critical applications. Cheaper uncoated or poorly plated hardware will corrode within 12–24 months in professional touring use. Always specify corrosion-resistant finishes – nickel-plated or stainless steel – for long-term reliability.

What load capacity do I need for case castors?

Calculate required castor load rating by dividing total loaded case weight (case plus equipment) by the number of wheels, then multiply by 1.5 safety factor to account for uneven load distribution and impact forces during transport. For example, a case with 80 kg total weight on four castors requires: (80 kg ÷ 4) × 1.5 = 30 kg per wheel minimum rating. Riggatec Blue Wheel 100 mm diameter castors rated to 80 kg per wheel provide adequate capacity; 160 mm diameter castors rated to 200 kg per wheel offer additional safety margin for heavier cases. Always specify braked castors on at least two wheels (diagonal configuration) to prevent unwanted movement during loading. For cases exceeding 150 kg total weight, heavy-duty castors with ball-bearing swivel mechanisms ensure smooth rolling and long service life.

How do I calculate material quantities for a custom case project?

Calculate material quantities by determining case external dimensions first, then working backwards to component requirements. For a case with 600×400×200 mm internal dimensions and 9 mm plywood with 30 mm aluminium profiles: Panels – base 618×418 mm, lid 618×418 mm, front/back 618×200 mm (×2), sides 400×200 mm (×2); total plywood area approximately 0.9 m². Aluminium profile – perimeter (600+400)×2 = 2000 mm, height 200 mm×4 corners = 800 mm; total profile length 2.8 m (order 3 m allowing cutting waste). Hardware – butterfly latches: one per 400 mm perimeter = 5 latches; ball corners: 8 pieces (4 base, 4 lid); handles: 2 recessed side handles; hinges: 600 mm piano hinge or 3 separate lid hinges. Foam – base layer 580×380 mm, lid layer 580×380 mm; order 1200×800 mm sheet. Always add 10–15% material allowance for cutting waste and measurement errors.

Case hardware

Adam Hall 19" Parts 872213 19" U-Rackblende 1 HE für 12 Buchsen

Adam Hall 19" Parts 872213 - 19" U-Shaped Rack Panel 12 Sockets 1 U

19" U-Shaped Rack Panel 12 Sockets 1 U 1 U rack panel with punched holes for 12 universal „D" type XLR sockets. : Product type: 19" Rack Panels • Material: Steel...

€7.13 *

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Adam Hall 19" Parts 8721 STL 19" Rackblende 1 HE, Stahl

Adam Hall 19" Parts 8721 STL - 19" Flat Rack Panel Steel, 1 U

19" Flat Rack Panel Steel, 1 U : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 1 U • Width: 19 "...

€4.57 *

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Adam Hall Hardware 4291 Stabilisierungskreuz 9,2 mm

Adam Hall Hardware 4291 - Cross for Dividing Walls 9.2 mm

Cross for Dividing Walls 9.2 mm : Product type: Flightcase Partitioning • Type: dividing wall hardware • Material: Steel • Surface: galvanized • Material thickness: 1.2 mm...

€1.48 *

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Adam Hall Hardware 4043 L-Ecke 40 x 28 verzinkt mit Kuppe

Adam Hall Hardware 4043 - Corner Brace 40 x 28 with Bulge

Corner Brace 40 x 28 with Bulge : Product type: Corner Braces • Material: Steel • Surface: galvanized • Color: silver • Material thickness: 1.2 mm • Mounting hole diameter:...

€0.31 *

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OMNITRONIC Modul 2HE 1x Kaltgerätedose 44x88mm

OMNITRONIC Module 2U 1x IEC female 44x88mm

2 U • Housing design: 2 U • Weight: 0,38 kg •

€0.75 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

OMNITRONIC Modul 2HE Blindplatte 44x88mm

OMNITRONIC Module 2U plate 44x88mm

2 U • Housing design: 2 U • Weight: 0,03 kg •

€1.02 *

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Delivery time: 3-5 days

Delivery time: 3-5 days

Adam Hall Hardware 58012 Verstärkungsplatte für 5801 Flugöse

Adam Hall Hardware 58012 - Back Plate for 5801 D-Ring

Back Plate for 5801 D-Ring Back Plate for D-Ring 5801 : Product type: Speaker Construction Accessories • Type: Flyware • Material: Steel • Surface: galvanized • Width: 95 mm...

€1.34 *

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Adam Hall Hardware 34704 Aufbau-Ausziehgriff 2 Auszüge

Adam Hall Hardware 34704 - Extendable Handle 2-stage length 420 - 935 mm

Extendable Handle 2-stage length 420 - 935 mm Extendable handle, flat external mount • three part: 37/28/28 cm • : Product type: Handles • Type: Pull-out Handles • Extensions: 2...

€37.09 *

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Adam Hall Hardware 27096 Deckelfeststeller mittel ungekröpft mit Scharnier

Adam Hall Hardware 27096 - Lid Stay Medium non Cranked with Hinge and Click-Stop Function

Lid Stay Medium non Cranked with Hinge and Click-Stop Function : Product type: Hinges and Lidstays • Type: lid stay • Dish material: Steel • Dish surface: galvanized • Dish...

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€6.85 *

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Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 1630 KEEP Aufbauschließe für 17302 Stahl verzinkt

Adam Hall Hardware 1630 KEEP - Keeper Plate for 17302 Galvanized Steel

Keeper Plate for 17302 Galvanized Steel Surface mount keeper plate : Product type: Catch Accessories • Color: silver • Material: Steel • Surface: galvanized • Mounting hole...

€0.82 *

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Adam Hall Hardware 16543 Haltewinkel Stahl verzinkt

Adam Hall Hardware 16543 - Keeper Plate Steel Galvanized

Keeper Plate Steel Galvanized Bracket for simple attachment of lid to the flush lid system extrusion on the opposite side of the lid to the sliding latch. : Height: 82 mm • Width: 28 mm...

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€1.23 *

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Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 58155 Dämmwatte weiß 25 mm

Adam Hall Hardware 58155 - Wadding white 1500mm x 25 mm

Wadding white 1500mm x 25 mm Insulating wadding for loudspeaker boxes and sound absorption : Product type: Speaker Construction Accessories • Type: Wadding • Width: 1500 mm...

€22.46 *

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ROADINGER Schaumstoffeinsatz 576x376x100mm

ROADINGER Foam Material for 576x376x100mm

Dimensions: Width: 57,6 cm Depth: 37,6 cm Height: 10 cm • Weight: 0,51 kg •

€29.90 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

OMNITRONIC Rackwinkel für Verstärker, hinten, 3HE

OMNITRONIC Rack Bracket for Amplifier, back, 3U

Rack brackets for amplifiers, 3 U 3 U • Housing design: 3 U • Weight: 0,55 kg •

€15.50 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

MONACOR RCP-8701U 482 mm (19") rack panel, 1 RS

482 mm (19") rack panel, 1 RS, closed. 1.5 mm steel, black plastic coating • Upper and lower edges angled (8 mm) in different configurations • Ideally suited for individual...

€7.00 *

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Delivery time: 3-5 days

Delivery time: 3-5 days

SHOWGEAR Egg Foam 30 mm Set of 2 sheets of 1.5 m x 2 m

Set of 2 sheets of 1.5 m x 2 m : Length (mm): 1500 mm • Height (mm): 30 mm • Width (mm): 2000 mm • Fabric: Foam • Fabric Thickness: 30 mm • Colour: Gray •

€144.33 *

incl. tax, free shipping to Germany
[International shipping costs]

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

DAP Schaumdämmung Pearl, Dicke: 20mm Größe: 1m x 1.3m

SHOWGEAR Pearl Foam 20 mm Sheet of 1 m x 1.3 m

Sheet: 1 m x 1.3 m : Length (mm): 1000 mm • Height (mm): 20 mm • Width (mm): 1300 mm • Fabric: Foam • Fabric Thickness: 20 mm • Colour: Gray •

€31.45 *

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Delivery time: 3-5 days

Delivery time: 3-5 days

SHOWGEAR 19 Inch Protection Panel with Locker 2U

19"/2U : Rack Units: 2 U • Colour: Black / Transparent • Height (mm): 88.9 mm • Width (mm): 482.6 mm • Flightcase Size: 19" • Material: Metal • Material...

€23.90 *

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Delivery time: 3-5 days

Delivery time: 3-5 days

Adam Hall Hardware 3476033 Versenkter Ausziehgriff 2 Auszüge, verzinkte Sc

Adam Hall Hardware 3476033 - Recessed Extendable Handle 2-stage, zinc-plated cranked Dish length

Recessed Extendable Handle 2-stage, zinc-plated cranked Dish length 336 - 661 mm Recessed extendable handle with two stages Locking mechanism with release button in the handle • to be mounted...

€52.81 *

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Adam Hall Hardware 8705 BLK Einbauschale schwarz ungestanzt

Adam Hall Hardware 8705 BLK - Dish black unpunched

Dish black unpunched Dish Opening Size: 115 x 67 mm • : Product type: Recessed Dishes • Dish material: Steel • Dish surface: Powder coated • Dish colour: Black • Dish...

€1.96 *

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Adam Hall Hardware 8705 Einbauschale verzinkt ungestanzt

Adam Hall Hardware 8705 - Dish Galvanized Unpunched

Dish Galvanized Unpunched Dish Opening Size: 115 x 67 mm • : Product type: Recessed Dishes • Dish material: Steel • Dish surface: galvanized • Dish colour: silver • Dish...

€1.52 *

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Adam Hall Hardware 019615 Plastazote (LD29) mit 7 mm Nuten 15 mm

Adam Hall Hardware 019615 - Plastazote (LD29) with 7 mm Grooves 15 mm

Plastazote (LD29) with 7 mm Grooves 15 mm PE foam "Plastazote" : Product type: Coverings and Foam Materials • Type: Foam Materials • Color: Black • Material: Plastazote...

€100.64 *

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Bulky goods