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

Riggatec Lenkrollensatz 160mm BLUE WHEEL 4x ohne Bremse

Riggatec swivel castor set 160mm BLUE WHEEL 4x without brake

Riggatec Blue Wheels swivel castor set 160 mm without brake – robust transport castors for a wide range of applications Riggatec Blue Wheels offer a premium mobility solution with high load...

€58.00 * €54.90 *

Content: 4 itm (€13.73 * / 1 itm)

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Riggatec Lenkrollensatz 200mm BLUE WHEEL 4x mit Bremse

Riggatec 200mm BLUE WHEEL swivel castor set 4x with brake

Riggatec Blue Wheels swivel castor set 200 mm with brake – Sturdy transport castors for a wide range of applications Riggatec Blue Wheels offer a premium mobility solution with high load...

€91.60 * €87.90 *

Content: 4 itm (€21.98 * / 1 itm)

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

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Riggatec Lenkrollensatz 200mm BLUE WHEEL 4x ohne Bremse

Riggatec 200mm BLUE WHEEL swivel castor set 4x without brake

Riggatec Blue Wheels swivel castor set 200 mm without brake – robust transport castors for a wide range of applications Riggatec Blue Wheels offer a premium mobility solution with high load...

€85.96 *

Content: 4 itm (€21.49 * / 1 itm)

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

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Manfrotto - 110G - Rädersatz Ø100 mm/22 mm Bremse

Manfrotto - 110G - Wheel Set of 3 100mm with brakes and adapter for legs

All Manfrotto stands provide for a high level of customisation, thanks to a wide range of accessories like wheels, sand bags,clips, wind-bracing kit and stans holder that can accept any lighting...

€109.00 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 61535 B 18 HD Rackschiene schwarz 18 HE

Adam Hall 19" Parts 61535 B 18 - Heavy Duty Rack Strip black 18 U

Heavy Duty Rack Strip black 18 U Heavy duty rack strip, similar to 61352BLK, but with three holes per U 9.5 mm hole size (according to IEC 60297) • : Product type: 19" Rack Strips...

€9.23 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 8721 V 19" Lüftungsblende 1 HE, vertikale Lüftungsschl

Adam Hall 19" Parts 8721 V - 19" Flat Ventilation Panel 1U with Vertical Slots

19" Flat Ventilation Panel 1U with Vertical Slots Ventilation Rack Panel : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black...

€7.25 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 872212 19" U-Rackblende 1 HE, universal

Adam Hall 19" Parts 872212 - 19" U-Shaped Rack Panel Universal 1 U

19" U-Shaped Rack Panel Universal 1 U 1 U rack pannel with punched holes for 2 x female XLR, 6 x male XLR and 1 x IEC mains socket. : Product type: 19" Rack Panels • Material: Steel...

€10.90 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 872214 19" U-Rackblende 2 HE für 24 Buchsen

Adam Hall 19" Parts 872214 - 19" U-Shaped Rack Panel 24 Sockets 2 U

19" U-Shaped Rack Panel 24 Sockets 2 U 2 U rack panel with punched holes for 24 universal „D" type XLR sockets. : Product type: 19" Rack Panels • Material: Steel...

€10.70 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 872215 19" U-Rackblende 1 HE mit Zugentlastung für 12

Adam Hall 19" Parts 872215 - 19" U-Shaped Rack Panel 12 Sockets 1 U with Tie Bar

19" U-Shaped Rack Panel 12 Sockets 1 U with Tie Bar 1 U rack panel with punched holes for 12 universal „D“ type XLR sockets With integral strain relief • Integrated tie bar...

€11.95 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87221 VH 19" U-Lüftungsblende 1 HE, horizontale Lüftun

Adam Hall 19" Parts 87221 VH - 19" U-Shaped Ventilation Panel with Horizontal Slots, 1 U

19" U-Shaped Ventilation Panel with Horizontal Slots, 1 U U-shaped Ventilation Rack Panel - horizontal slots : Product type: 19" Rack Panels • Material: Steel • Surface: Powder...

Express delivery possible

€5.72 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall 19" Parts 87221 VR 19" U-Lüftungsblende 1 HE, Rundlochung

Adam Hall 19" Parts 87221 VR - 19" U-Shaped Ventilation Panel with Round Holes, 1 U

19" U-Shaped Ventilation Panel with Round Holes, 1 U U-shaped vent with round holes Ventilation area 88 cm² : Product type: 19" Rack Panels • Material: Steel • Surface:...

€5.13 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87222 19" U-Rackblende 2 HE, Aluminium

Adam Hall 19" Parts 87222 - 19" U-Shaped Rack Panel 2 U Aluminium

19" U-Shaped Rack Panel 2 U Aluminium : Product type: 19" Rack Panels • Material: Aluminium • Surface: Powder coated • Color: Black • Height: 2 U • Width: 19...

€9.75 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 872225 19" U-Rackblende 1 HE mit Zugentlastung für 16

Adam Hall 19" Parts 872225 - 19" U-Shaped Rack Panel 16 Sockets 1U with Tie Bar

19" U-Shaped Rack Panel 16 Sockets 1U with Tie Bar 1 U rack panel with punched holes for 16 universal „D“ type XLR sockets. With integral strain relief • Integrated tie bar...

€11.71 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87222 STL 19" U-Rackblende 2 HE, Stahl

Adam Hall 19" Parts 87222 STL - 19" U-Shaped Rack Panel 2 U Steel

19" U-Shaped Rack Panel 2 U Steel : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 2 U • Width: 19 "...

€6.25 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87222 VH 19" U-Lüftungsblende 2 HE, horiz. Lüftung

Adam Hall 19" Parts 87222 VH - 19" U-Shaped Ventilation Panel with Horizontal Slots, 2U

19" U-Shaped Ventilation Panel with Horizontal Slots, 2U U-shaped Ventilation Rack Panel - horizontal slots : Product type: 19" Rack Panels • Material: Steel • Surface: Powder...

€9.21 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87223 19" U-Rackblende 3 HE, Aluminium

Adam Hall 19" Parts 87223 - 19" U-shaped Rack Panel 3 U aluminium

19" U-shaped Rack Panel 3 U aluminium : Product type: 19" Rack Panels • Material: Aluminium • Surface: Powder coated • Color: Black • Height: 3 U • Width: 19 mm...

€13.79 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 872230 19" gewinkelte Rackblende für 8x D-TYPE Buchsen

Adam Hall 19" Parts 872230 - 19" Angled Rack Panel for 8 x D-TYPE Sockets

19" Angled Rack Panel for 8 x D-TYPE Sockets 19" angled rack panel with 8 cutouts for D-type sockets - with rear strain relief rail. The mounting holes are fitted with M3 threads; the...

€28.89 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87223 STL 19" U-Rackblende 3 HE, Stahl

Adam Hall 19" Parts 87223 STL - 19" U-Shaped Rack Panel 3 U Steel

19" U-Shaped Rack Panel 3 U Steel : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 3 U • Width: 19 "...

€9.23 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87224 19" U-Rackblende 4 HE, Aluminium

Adam Hall 19" Parts 87224 - 19" U-Shaped Rack Panel 4 U Aluminium

19" U-Shaped Rack Panel 4 U Aluminium : Product type: 19" Rack Panels • Material: Aluminium • Surface: Powder coated • Color: Black • Height: 4 U • Width: 19...

€17.43 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87224 STL 19" U-Rackblende 4 HE, Stahl

Adam Hall 19" Parts 87224 STL - 19" U-Shaped Rack Panel 4 U Steel

19" U-Shaped Rack Panel 4 U Steel : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 4 U • Width: 19 "...

€9.51 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 8722 STL 19" Rackblende 2 HE, Stahl

Adam Hall 19" Parts 8722 STL - 19" Flat Rack Panel Stahl, 2U

19" Flat Rack Panel Stahl, 2U : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 2 U • Width: 19 "...

€6.25 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 8723 19" Rackblende 3 HE, Aluminium

Adam Hall 19" Parts 8723 - 19" Flat Rack Panel Aluminium, 3U

19" Flat Rack Panel Aluminium, 3U : Product type: 19" Rack Panels • Material: Aluminium • Surface: Powder coated • Color: Black • Height: 3 U • Width: 19 "...

€12.60 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 8723 STL 19" Rackblende 3 HE, Stahl

Adam Hall 19" Parts 8723 STL - 19" Flat Rack Panel Steel, 3U

19" Flat Rack Panel Steel, 3U : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 3 U • Width: 19 "...

€9.23 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 8724 19" Rackblende 4 HE, Aluminium

Adam Hall 19" Parts 8724 - 19" Flat Rack Panel Aluminium, 4U

19" Flat Rack Panel Aluminium, 4U : Product type: 19" Rack Panels • Material: Aluminium • Surface: Powder coated • Color: Black • Height: 4 U • Width: 19 "...

€19.35 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week