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 1656 Hebelverschluss Kunststoff schwarz

Adam Hall Hardware 1656 - Lever Latch plastic black

Lever Latch plastic black Recessed lever latch for service door. Black plastic (POM). Mounts into wood thickness from 7-13 mm. Stainless steel screws. : Product type: Catches • Type: Lever...

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€14.51 *

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Adam Hall Hardware 17302 Overlatch Butterfly Verschluss groß 14 mm tief

Adam Hall Hardware 17302 - Overlatch Butterfly Latch Large 14 mm Deep

Overlatch Butterfly Latch Large 14 mm Deep Overlatch butterfly large in dish. Compatible lock available: 1630KEEP : Product type: Catches • Type: Butterfly Latches • Material: Steel...

€11.90 *

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Adam Hall Hardware 17343 Overlatch Butterfly Verschluss klein 9 mm tief

Adam Hall Hardware 17343 - Overlatch Butterfly Latch Small 9 mm Deep

Overlatch Butterfly Latch Small 9 mm Deep Small overlatching butterfly catch in dish. Can be used with Hybrid locations with keep and with 6124 without keep. • Keep available: 1632KEEP :...

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€7.78 *

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Adam Hall Hardware 2508 Feststellscharnier mittel verchromt

Adam Hall Hardware 2508 - Stop Hinge medium chrome-plated

Stop Hinge medium chrome-plated Medium stop-hinge. Stops at 95°. : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: chromium plated • Material...

€1.12 *

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Adam Hall Hardware 2527 Feststellscharnier mittel vernickelt

Adam Hall Hardware 2527 - Stop Hinge medium nickel-plated

Stop Hinge medium nickel-plated Medium strut hinge : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: nickel plated • Material thickness: 0.6 mm...

€1.37 *

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Adam Hall Hardware 2528 Feststellscharnier mittel vernickelt

Adam Hall Hardware 2528 - Stop Hinge medium nickel-plated

Stop Hinge medium nickel-plated Medium strut hinge : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: nickel plated • Material thickness: 1 mm...

€1.54 *

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Adam Hall Hardware 2601 Scharnier klein verzinkt

Adam Hall Hardware 2601 - Hinge Small Galvanized

Hinge Small Galvanized Hinge small Fits on lid location 6102. • : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: galvanized • Material...

€1.11 *

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Adam Hall Hardware 2605 Klavierband Stahl vorgebohrt

Adam Hall Hardware 2605 - Piano Hinge steel pre-drilled

Piano Hinge steel pre-drilled Piano hinge - punched at 76 mm centres : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: galvanized • Material...

€16.73 *

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Adam Hall Hardware 2701 Kofferdeckel Feststeller Stahl vernickelt

Adam Hall Hardware 2701 - Case Lid Stay steel nickel-plated

Case Lid Stay steel nickel-plated : Product type: Hinges and Lidstays • Type: lid stay • Material: Steel • Surface: nickel plated • Material thickness: 1.5 mm • Length: 74...

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€2.25 *

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Adam Hall Hardware 2808 Kofferinlett Netztasche

Adam Hall Hardware 2808 - Net Bag Case Insert

Net Bag Case Insert Net pocket with zip - Velcro (Hooks) on back enable removal of attachment from case lid. : Product type: Flightcase Accessories • Color: Black • Material: Synthetic...

€7.28 *

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Adam Hall Hardware 34001 Schalengriff Stahl schwarz pulverbeschichtet

Adam Hall Hardware 34001 - Bar Handle steel black powder-coated

Bar Handle steel black powder-coated : Product type: Handles • Type: Insert Handles • Material: Steel • Surface: Powder coated • Color: Black • Material thickness: 1 mm...

€7.03 *

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Adam Hall Hardware 3403 Griffschale Kunststoff schwarz

Adam Hall Hardware 3403 - Insert Handle plastic black

Insert Handle plastic black Insert handle - in two parts Can be used to lift a box from all four directions • With holes for water drain. • : Product type: Handles • Type: Insert...

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€6.24 *

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Adam Hall Hardware 34030 Schale Kunstoff für Montage bei Griffausschnitten

Adam Hall Hardware 34030 - Plastic Dish for Mounting inside Handle Cutouts black

Plastic Dish for Mounting inside Handle Cutouts black Dish for mounting inside a loudspeaker cabinet to airseal routed handled cutout. : Product type: Handles • Type: Insert Handles...

€5.95 *

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Adam Hall Hardware 3405 Schalengriff für Kantenmontage schwarz

Adam Hall Hardware 3405 - Bar Handle for Edge Mounting black

Bar Handle for Edge Mounting black Recessed steel Bar Handle for top edge mounting. : Product type: Handles • Type: Insert Handles • Material: Steel • Surface: Powder coated...

€8.03 *

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Adam Hall Hardware 34062 Schalengriff Kunststoff schwarz

Adam Hall Hardware 34062 - Installation Shell Handle Round, Plastic

Installation Shell Handle Round, Plastic Bar Handle : Product type: Handles • Type: Insert Handles • Material: Plastic • Surface: nature • Color: Black • Handle height: 190...

€7.78 *

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Adam Hall Hardware EVOLUTIVE HANDLE Ergonomischer Schalengriff, zweiteilig

Adam Hall Hardware EVOLUTIVE HANDLE - Ergonomic installation "Evolution" handle in set (2 pieces)".

Ergonomic installation "Evolution" handle in set (2 pieces)". Handle consisting of a black plastic dish and a sturdy ring handle made of black powder-coated die-cast zinc. By virtue...

€26.25 *

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Adam Hall Hardware 3407 Verstärkungsplatte für 34102 Klappgriff

Adam Hall Hardware 3407 - Back Plate for 34102 Recessed Sprung Handle

Back Plate for 34102 Recessed Sprung Handle Back plate for recessed handle 34102. : Product type: Handle Accessories • Material: Steel • Material thickness: 1 mm • Surface:...

€1.27 *

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Adam Hall Hardware 34081 Klappgriff mittel gefedert in Einbauschale 9 mm t

Adam Hall Hardware 34081 - Medium Spring Loaded Flip Handle

Medium Spring Loaded Flip Handle In 9 mm deep dish with rivet protection • Zinc plated steel, 5.1 mm mounting holes • : Product type: Handles • Type: Folding Handles • Dish...

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€5.46 *

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Adam Hall Hardware 34082 A Klappgriff mittel gefedert in Einbauschale Alum

Adam Hall Hardware 34082 A - Recessed Sprung Handle medium in Dish aluminium 8 mm deep

Recessed Sprung Handle medium in Dish aluminium 8 mm deep In 9 mm deep dish with rivet protection • Zinc plated steel, 5.1 mm mounting holes • : Product type: Handles • Type: Folding...

€8.77 *

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Adam Hall Hardware 34082 S Klappgriff mittel gefedert in Einbauschale Edel

Adam Hall Hardware 34082 S - Recessed Sprung Handle medium in Dish Stainless steel 8 mm deep

Recessed Sprung Handle medium in Dish Stainless steel 8 mm deep In 9 mm deep dish with rivet protection • Zinc plated steel, 5.1 mm mounting holes • : Product type: Handles • Type:...

€11.22 *

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Adam Hall Hardware 34085 Klappgriff groß gefedert in Einbauschale 14 mm ti

Adam Hall Hardware 34085 - Recessed Sprung Handle large in Dish 14 mm deep

Recessed Sprung Handle large in Dish 14 mm deep In 14 mm deep dish with rivet protection • Zinc plated steel, 5.1 mm mounting holes • : Product type: Handles • Type: Folding Handles...

€6.63 *

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Adam Hall Hardware 34093 Verstärkungsplatte für 34082 Klappgriff

Adam Hall Hardware 34093 - Back Plate for 34082 Recessed Sprung Handle

Back Plate for 34082 Recessed Sprung Handle Back plate for recessed handle 34082. Backing Plate for use with wood > 8 mm. : Product type: Handle Accessories • Material: Steel...

€1.26 *

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Adam Hall Hardware 34095 Verstärkungskranz für 34085 Klappgriff

Adam Hall Hardware 34095 - Backing Ring for 34085 Recessed Sprung Handle

Backing Ring for 34085 Recessed Sprung Handle Back plate for recessed handle 34085. : Product type: Handle Accessories • Material: Steel • Material thickness: 1 mm • Surface:...

€1.67 *

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Adam Hall Hardware 34097 Verstärkungskanz für 34081/3 Klappgriff

Adam Hall Hardware 34097 - Backing Ring for 34081/3 Recessed Sprung Handle

Backing Ring for 34081/3 Recessed Sprung Handle Backing Ring for use with handle 34081 / 34083. : Product type: Handle Accessories • Material: Steel • Material thickness: 1 mm...

€1.26 *

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