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 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 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

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 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

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 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

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 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 34098 Verstärkungsplatte für 34081/3 Klappgriff

Adam Hall Hardware 34098 - Back Plate for 34081/3 Recessed Sprung Handle

Back Plate for 34081/3 Recessed Sprung Handle Back plate for recessed handle 34081 / 34083. : Product type: Handle Accessories • Material: Steel • Material thickness: 1 mm • Surface:...

€1.26 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 34102 Klappgriff mittel gefedert in großer Einbauschale

Adam Hall Hardware 34102 - Recessed Sprung Handle medium in large Dish 9,5 mm deep

Recessed Sprung Handle medium in large Dish 9,5 mm deep In 9 mm deep dish with rivet protection • Zinc plated steel, 5.1 mm mounting holes • : Product type: Handles • Type: Folding...

€5.11 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3412 Klappgriff klein gefedert

Adam Hall Hardware 3412 - Surface Mounted Handle Small

Surface Mounted Handle Small Zinc plated steel, 5.1 mm mounting holes • : Product type: Handles • Type: Folding Handles • Dish material: Steel • Dish surface: galvanized...

Express delivery possible

€4.55 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 3414 BRN Riemengriff Kunstleder braun

Adam Hall Hardware 3414 BRN - Strap Handle Leatherette brown

Strap Handle Leatherette brown Strap handle with Steel insert nickel plated mounting brackets • Supplied with 4 tee nuts and 4 screws (M4x25). • : Product type: Handles • Type: Strap...

€16.24 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3415 Koffergriff Kunstleder schwarz

Adam Hall Hardware 3415 - Case Handle Leather black

Case Handle Leather black With elastic inner stay • Nickel-plated mountings • : Product type: Handles • Type: Strap and Briefcase-type Handles • Handle material: leather...

Express delivery possible

€9.19 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 3416 Koffergriff Leder schwarz

Adam Hall Hardware 3416 - Case Handle Leather black

Case Handle Leather black With elastic inner stay • Nickel-plated mountings • : Product type: Handles • Type: Strap and Briefcase-type Handles • Handle material: leather...

Express delivery possible

€8.00 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 3419 Riemengriff Kunststoff schwarz

Adam Hall Hardware 3419 - Strap Handle plastic black

Strap Handle plastic black Heavy duty plastic covered Strap Handle with steel inner core • steel fixing plates with nickel plated caps • : Product type: Handles • Type: Strap and...

€8.94 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3423 Riemengriff Kunststoff Endkappen schwarz

Adam Hall Hardware 3423 - Strap Handle plastic, End Caps black

Strap Handle plastic, End Caps black Heavy duty plastic covered Strap Handle with steel inner core. • End plates made of steel, black powder coated • : Product type: Handles • Type:...

Express delivery possible

€2.20 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 3423 AH Riemengriff Kunststoff Endkappen schwarz im Beu

Adam Hall Hardware 3423 AH - Strap Handle Plastic, End Caps black in Bag

Strap Handle Plastic, End Caps black in Bag Heavy duty plastic covered Strap Handle with steel inner core. • End plates made of steel, black powder coated • : Product type: Handles...

Express delivery possible

€4.91 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 3426 Riemengriff Kunststoff schwarz 300 mm

Adam Hall Hardware 3426 - Strap Handle plastic black 300 mm

Strap Handle plastic black 300 mm Black Plastic Strap Handle - Heavy Duty with steel insert • Polycarbonate end plates • : Product type: Handles • Type: Strap and Briefcase-type...

Express delivery possible

€2.15 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 3427 Riemengriff Kunststoff schwarz 280 mm

Adam Hall Hardware 3427 - Strap Handle plastic black 280 mm

Strap Handle plastic black 280 mm Black Plastic Strap Handle - Heavy Duty with steel insert • Polycarbonate end plates • : Product type: Handles • Type: Strap and Briefcase-type...

€2.15 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3440 Klappgriff zweiteilig verzinkt

Adam Hall Hardware 3440 - Drop Handle Two-piece Galvanized

Drop Handle Two-piece Galvanized : Product type: Handles • Type: Folding Handles • Dish material: Steel • Dish surface: galvanized • Dish colour: silver • Handle height: 80...

Express delivery possible

€2.01 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 3473 Versenkter Ausziehgriff 3 Auszüge

Adam Hall Hardware 3473 - Recessed Extendable Handle 3-stage length 395 - 895 mm

Recessed Extendable Handle 3-stage length 395 - 895 mm Recessed extendable handle Entire assembly mounts inside case, handle is recessed. : Product type: Handles • Type: Pull-out Handles...

€52.09 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 34733 Versenkter ausklappbarer Trolleygriff

Adam Hall Hardware 34733 - Recessed fold-out Handle length 434 - 684 mm

Recessed fold-out Handle length 434 - 684 mm Recessed extendable handle which folds back into dish • recessed fitting without loss of internal space • : Product type: Handles • Type:...

€45.36 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3476021 Versenkter Ausziehgriff 1 Auszug, schwarze Scha

Adam Hall Hardware 3476021 - Recessed Extendable Handle 1-stage, black cranked Dish length 528 -

Recessed Extendable Handle 1-stage, black cranked Dish length 528 - 808 mm Recessed extendable handle with one stage Locking mechanism with release button in the handle • to be mounted inside...

€53.47 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3476023 Versenkter Ausziehgriff 1 Auszug, verzinkte Sch

Adam Hall Hardware 3476023 - Recessed Extendable Handle 1-stage, zinc-plated cranked Dish length

Recessed Extendable Handle 1-stage, zinc-plated cranked Dish length 528 - 808 mm Recessed extendable handle with one stage Locking mechanism with release button in the handle • to be mounted...

€53.47 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3476031 Versenkter Ausziehgriff 2 Auszüge, schwarze Sch

Adam Hall Hardware 3476031 - Recessed Extendable Handle 2-stage, black cranked Dish length 336 -

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

€53.56 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3476041 Versenkter Ausziehgriff 3 Auszüge, schwarze Sch

Adam Hall Hardware 3476041 - Recessed Extendable Handle 3-stage, black cranked Dish length 336 -

Recessed Extendable Handle 3-stage, black cranked Dish length 336 - 856 mm Recessed extendable handle with three stages Locking mechanism with release button in the handle • to be mounted...

€56.60 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3476043 Versenkter Ausziehgriff 3 Auszüge, verzinkte Sc

Adam Hall Hardware 3476043 - Recessed Extendable Handle 3-stage, zinc-plated cranked Dish length

Recessed Extendable Handle 3-stage, zinc-plated cranked Dish length 336 - 856 mm Recessed extendable handle with three stages Locking mechanism with release button in the handle • to be...

€56.60 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 3480 Kombinierter Griff/Fuß

Adam Hall Hardware 3480 - Combination Handle/Foot

Combination Handle/Foot enables case to be lifted from bottom. : Product type: Handles • Type: Strap and Briefcase-type Handles • Material: Polypropylene • Color: Black • Width:...

€2.15 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week