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 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 "...

€15.58 *

incl. tax, plus shipping costs

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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 *

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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 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 87407 V 19" Leergehäuse 1 HE mit Lüftungsschlitzen

Adam Hall 19" Parts 87407 V - 19" Housing 1 U rackmount with Vent Slots

19" Housing 1 U rackmount with Vent Slots 19" Housing, with ventilation slots in top panel • Flat-packed with screws • : Product type: 19" Rack Accessories • Material:...

€53.19 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 87409 V 19" Leergehäuse 3 HE mit Lüftungsschlitzen

Adam Hall 19" Parts 87409 V - 19" Housing 3 U rackmount with Vent Slots

19" Housing 3 U rackmount with Vent Slots 19" Housing, with ventilation slots in top panel • Flat-packed with screws • : Product type: 19" Rack Accessories • Material:...

€81.71 *

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

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Delivery time: approx. 1 week

Adam Hall 19" Parts 87445 19" Lochblechabdeckung 1 HE, grobe Lochung

Adam Hall 19" Parts 87445 - 19" Cover with Punched Hole Front, 1U, Coarse

19" Cover with Punched Hole Front, 1U, Coarse 19" cover with punched hole front for protecting settings on effects unis, etc. • : Product type: 19" Rack Panels • Material:...

€14.24 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 87446 19" Lochblechabdeckung 2 HE, grobe Lochung

Adam Hall 19" Parts 87446 - 19" Cover with Punched Hole Front, 2U, Coarse

19" Cover with Punched Hole Front, 2U, Coarse 19" cover with punched hole front for protecting settings on effects unis, etc. • : Product type: 19" Rack Panels • Material:...

€15.18 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 87447 19" Lochblechabdeckung 3 HE, grobe Lochung

Adam Hall 19" Parts 87447 - 19" Cover with Punched Hole Front, 3U, Coarse

19" Cover with Punched Hole Front, 3U, Coarse 19" cover with punched hole front for protecting settings on effects unis, etc. • : Product type: 19" Rack Panels • Material:...

Express delivery possible

€16.49 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall 19" Parts 87610 19" Serviceklappe Höhe 27 cm

Adam Hall 19" Parts 87610 - 19" Rack Door 27 cm height

19" Rack Door 27 cm height : Product type: 19" Rack Accessories • Material: Steel • Surface: Powder coated • Color: Black • Width: 19" • Height: 270 mm...

€81.27 *

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

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Delivery time: approx. 1 week

Adam Hall 19" Parts 8763 19" Rackblende für 2 Axial-Lüfter

Adam Hall 19" Parts 8763 - 19" Rack Panel for 2 Axial Fans

19" Rack Panel for 2 Axial Fans Rack panel 3 U high for mounting up to 3 standard axial fans • For 2 fans • : Product type: 19" Rack Panels • Material: Steel...

€17.93 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 8765 19" Rackblende für 3 Axial-Lüfter

Adam Hall 19" Parts 8765 - 19" Rack Panel for 3 Axial Fans

19" Rack Panel for 3 Axial Fans Rack panel 3 U high for mounting of 3 standard axial fans • For 3 fans • : Product type: 19" Rack Panels • Material: Steel • Surface:...

€18.34 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 5650 Käfigmutter M6 für 3,5 mm

Adam Hall 19" Parts 5650 - Cage Nut M6 for 3,5 mm

Cage Nut M6 for 3,5 mm Cage nut M6 for 6150 (aluminium rear rail punched) • : Product type: Fittings • Type: cage nut • Material: Steel • Surface: galvanized • Color:...

Express delivery possible

€0.19 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall 19" Parts 5651 Käfigmutter M6 für 1,5 mm

Adam Hall 19" Parts 5651 - Cage Nut M6 for 1,5 mm

Cage Nut M6 for 1,5 mm M6 Cagenut (narrow slot) for 61552BLK rack strip • : Product type: Fittings • Type: cage nut • Material: Steel • Surface: chromium plated • Color:...

Express delivery possible

€0.33 *

incl. tax, plus shipping costs

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall 19" Parts 6150 Rackschiene Aluminium

Adam Hall 19" Parts 6150 - Rack Strip Aluminium

Rack Strip Aluminium : Product type: 19" Rack Strips • Type: punched • Material: Aluminium • Surface: nature • Color: nature • Length: 90 U • Material thickness:...

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€5.16 *

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Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall 19" Parts 61535 B 2 HD Rackschiene schwarz 2 HE

Adam Hall 19" Parts 61535 B 2 - Heavy Duty Rack Strip black 2 U

Heavy Duty Rack Strip black 2 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...

Express delivery possible

€2.23 *

incl. tax, plus shipping costs

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall 19" Parts 61535 B 5 HD Rackschiene schwarz 5 HE

Adam Hall 19" Parts 61535 B 5 - Heavy Duty Rack Strip black 5 U

Heavy Duty Rack Strip black 5 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...

€3.46 *

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Adam Hall 19" Parts 6168 Rackschiene Aluminium doppelt stufenlos mit Gummi

Adam Hall 19" Parts 6168 - Double Sliding Rack Strip System with rubber Insert aluminium

Double Sliding Rack Strip System with rubber Insert aluminium : Product type 19" Rack Strips • Type continuous • Material Aluminium • Surface nature • Color nature...

Express delivery possible

€12.82 *

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Details

Adam Hall 19" Parts 6169 Rackschiene Aluminium

Adam Hall 19" Parts 6169 - Rack Strip aluminium

Rack Strip aluminium Aluminium single sliding rack strip For side mounting shelf support in rear of racks with no rear double rack strip • Supplied with rubber insert for arresting special M6...

€6.02 *

incl. tax, plus forwarding agency costs

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Bulky goods

Adam Hall 19" Parts 87221 BRUSH Rackblende 1 HE Stahl mit Bürstenleiste

Adam Hall 19" Parts 87221 BRUSH - Rack Panel 1 U Steel with Brush Strip

Rack Panel 1 U Steel with Brush Strip U-shaped rack panel with brush strip to pass through connectors and cables : Product type: 19" Rack Panels • Material: Steel • Surface: Powder...

€17.67 *

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Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall 19" Parts 87222 BRUSH Rackblende 2 HE Stahl mit Bürstenleiste

Adam Hall 19" Parts 87222 BRUSH - Rack Panel 2 U Steel with Brush Strip

Rack Panel 2 U Steel with Brush Strip U-shaped rack panel with brush strip to pass through connectors and cables : Product type: 19" Rack Panels • Material: Steel • Surface: Powder...

€22.17 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 1602 Aufbauschloss groß mit Öse für Vorhängeschloss

Adam Hall Hardware 1602 - Drawbolt large padlockable

Drawbolt large padlockable Large padlocking drawbolt : Product type: Catches • Type: Drawbolt catches • Material: Steel • Surface: galvanized • Mounting hole diameter: 4.9 mm...

Express delivery possible

€2.06 * €1.56 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 1602 AH Aufbauschloss groß mit Öse für Vorhängeschloss

Adam Hall Hardware 1602 AH - Drawbolt Large Padlockable in Bag

Drawbolt Large Padlockable in Bag Large padlocking drawbolt : Product type: Catches • Type: Drawbolt catches • Material: Steel • Surface: galvanized • Mounting hole diameter:...

€4.20 *

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Delivery time: approx. 1 week

Adam Hall Hardware 1603 Aufbauschloss mit Öse für Vorhängeschloss

Adam Hall Hardware 1603 - Drawbolt padlockable

Drawbolt padlockable Medium drawbolt : Product type: Catches • Type: Drawbolt catches • Material: Steel • Surface: galvanized • Mounting hole diameter: 4.1 mm • Lockable:...

€2.52 *

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Delivery time: approx. 1 week

Adam Hall Hardware 1632 KEEP Aufbauschließe für 17343

Adam Hall Hardware 1632 KEEP - Keeper Plate for 17343

Keeper Plate for 17343 Surface mount keeper plate : Product type: Catch Accessories • Color: silver • Material: Steel • Surface: galvanized • Mounting hole diameter: 5.1 mm...

€0.86 *

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Availability:

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Delivery time: approx. 1 week

Delivery time: approx. 1 week