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 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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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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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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Adam Hall Hardware 16541 Ausgleichsblech

Adam Hall Hardware 16541 - Spacer

Spacer Sliding Latch System This sliding latch system was developed especially for small panels, doors or similar applications. In doing so, we emphasized minimising the installed height of the...

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€0.86 *

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Delivery time: 1-3 days

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Adam Hall Hardware 17233 Butterfly Verschluss klein in mittlerer Schale 9

Adam Hall Hardware 17233 - Butterfly Latch small in medium Dish lockable 9 mm deep

Butterfly Latch small in medium Dish lockable 9 mm deep Padlockable small butterfly catch mounted in a 9 mm deep dish. : Product type: Catches • Type: Butterfly Latches • Material: Steel...

€6.81 *

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Adam Hall Hardware 172501 Butterfly Verschluss groß ungekröpft 14 mm tief

Adam Hall Hardware 172501 - Butterfly Latch V3 large non cranked 14 mm deep

Butterfly Latch V3 large non cranked 14 mm deep Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and leads it back...

€12.72 *

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Adam Hall Hardware 17250 S Butterfly Verschluss groß gefedert ungekröpft 1

Adam Hall Hardware 17250 S - Butterfly Latch Large with Spring non Cranked 14 mm Deep

Butterfly Latch Large with Spring non Cranked 14 mm Deep The closing mechanism of the butterfly is equipped with a counter pressure spring to be automatically guided out at its opening position of...

€10.52 *

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Adam Hall Hardware 17250 SP Butterfly Verschluss groß gefedert ungekröpft

Adam Hall Hardware 17250 SP - Butterfly Latch Large with Spring non Cranked 14 mm Deep Padlockable

Butterfly Latch Large with Spring non Cranked 14 mm Deep Padlockable Butterfly large, with eyelet for a padlock. The closing mechanism of the butterfly is equipped with a counter pressure spring to...

€12.32 *

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Adam Hall Hardware 172511 Butterfly Verschluss groß gekröpft 14 mm tief

Adam Hall Hardware 172511 - Butterfly Latch V3 large cranked 14 mm deep

Butterfly Latch V3 large cranked 14 mm deep Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and leads it back into...

€12.72 *

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Adam Hall Hardware 17251 S Butterfly Verschluss groß gefedert gekröpft 14

Adam Hall Hardware 17251 S - Butterfly Latch Large with Spring Cranked 14 mm Deep

Butterfly Latch Large with Spring Cranked 14 mm Deep The closing mechanism of the butterfly is equipped with a counter pressure spring to be automatically guided out at its opening position of...

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€9.89 *

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 17251 SP Butterfly Verschluss groß gefedert gekröpft 14

Adam Hall Hardware 17251 SP - Butterfly Latch Large with Spring Cranked 14 mm Deep Padlockable

Butterfly Latch Large with Spring Cranked 14 mm Deep Padlockable Butterfly large, with eyelet for a padlock. The closing mechanism of the butterfly is equipped with a counter pressure spring to be...

€12.45 *

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Adam Hall Hardware 172530 Butterfly Verschluss kurz ungekröpft 14 mm tief

Adam Hall Hardware 172530 - Butterfly Latch V3 short non cranked 14 mm deep

Butterfly Latch V3 short non cranked 14 mm deep The same Large Butterfly "V3" with "push-down" function as in the 172501 but in a shorter dish. The entire mechanism is identical...

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€12.25 *

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Delivery time: 1-3 days

Adam Hall Hardware 172531 Butterfly Verschluss kurz gekröpft 14 mm tief

Adam Hall Hardware 172531 - Butterfly Latch V3 short cranked 14 mm deep

Butterfly Latch V3 short cranked 14 mm deep The same Large Butterfly "V3" with "push-down" function as in the 172511 but in a shorter dish. The entire mechanism is identical...

€11.82 *

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Adam Hall Hardware 172532 Butterfly Verschluss kurz gekröpft 14 mm tief mi

Adam Hall Hardware 172532 - Butterfly Latch V3 short cranked 14 mm deep with Rivet Protection

Butterfly Latch V3 short cranked 14 mm deep with Rivet Protection The same Large Butterfly "V3" with "push-down" function as in the 172511 but in a shorter dish. The entire...

€12.71 *

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Adam Hall Hardware 17254 S Butterfly Verschluss groß gefedert ungekröpft 1

Adam Hall Hardware 17254 S - Butterfly Latch Large with Spring non Cranked 10 mm Deep

Butterfly Latch Large with Spring non Cranked 10 mm Deep The closing mechanism of the butterfly is equipped with a counter pressure spring to be automatically guided out at its opening position of...

€9.83 *

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Adam Hall Hardware 17254 SP Butterfly Verschluss groß gefedert ungekröpft

Adam Hall Hardware 17254 SP - Butterfly Latch large with Spring non cranked 10 mm deep padlockable

Butterfly Latch large with Spring non cranked 10 mm deep padlockable Butterfly large, with eyelet for a padlock. The closing mechanism of the butterfly is equipped with a counter pressure spring to...

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€12.45 * €8.90 *

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Delivery time: 1-3 days

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Adam Hall Hardware 172571 Butterfly Verschluss groß gekröpft 7 mm tief mit

Adam Hall Hardware 172571 - Butterfly Latch V3 large cranked 7 mm deep with Rivet Protection

Butterfly Latch V3 large cranked 7 mm deep with Rivet Protection Large Butterfly with spring catch In an extremely shallow cranked dish • With the functionality of V3. • Our V3, V4 and V5...

€12.60 *

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Adam Hall Hardware 172572 Butterfly groß gekröpft 9 mm tief mit Nietschutz

Adam Hall Hardware 172572 - Butterfly Latch V3 large cranked 9 mm deep with Rivet Protection

Butterfly Latch V3 large cranked 9 mm deep with Rivet Protection Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and...

€12.72 *

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Adam Hall Hardware 172573 Butterfly groß gekröpft 14 mm tief mit Nietschut

Adam Hall Hardware 172573 - Butterfly Latch V3 large cranked 14 mm deep with Rivet Protection

Butterfly Latch V3 large cranked 14 mm deep with Rivet Protection Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening...

€13.49 *

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Adam Hall Hardware 172631 Butterfly Verschluss mittel gekröpft 12 mm tief

Adam Hall Hardware 172631 - Butterfly Latch short cranked 14 mm deep

Butterfly Latch short cranked 14 mm deep Our V5 Butterfly with enclosed mechanism in a cranked dish with rivet protection ridge. : Product type: Catches • Type: Butterfly Latches...

€12.71 *

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Adam Hall Hardware 17280 Butterfly Verschluss mittel ungekröpft 14 mm tief

Adam Hall Hardware 17280 - Butterfly Latch medium non cranked 14 mm deep

Butterfly Latch medium non cranked 14 mm deep Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and leads it back into...

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€6.50 *

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 17280 P Butterfly Verschluss mittel ungekröpft 14 mm ti

Adam Hall Hardware 17280 P - Butterfly Latch medium non cranked 14 mm deep padlockable

Butterfly Latch medium non cranked 14 mm deep padlockable Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and leads...

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€10.20 *

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Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 17283 Butterfly Verschluss mittel halb gekröpft 12 mm t

Adam Hall Hardware 17283 - Butterfly Latch medium half cranked 12 mm deep

Butterfly Latch medium half cranked 12 mm deep Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and leads it back...

€7.44 *

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Delivery time: approx. 1 week

Adam Hall Hardware 17284 Butterfly Verschluss mittel gekröpft 12 mm tief

Adam Hall Hardware 17284 - Butterfly Latch medium cranked 12 mm deep

Butterfly Latch medium cranked 12 mm deep Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and leads it back into the...

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€7.19 *

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days