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

Bralo 5596 Blindniete gerillt 3,2 mm x 10 mm

Bralo 5596 - Pop-Rivet grooved 3.2 mm x 10 mm

Pop-Rivet grooved 3.2 mm x 10 mm Single-sided application (blind rivet principle) • Secure connection in blind holes • Numerous grooves provide the right grip • Facilitates...

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€0.06 *

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Adam Hall Hardware 1607 AH Aufbauschloss mittel vernickelt im Beutel

Adam Hall Hardware 1607 AH - Drawbolt medium Nickel-Plated in Bag

Drawbolt medium Nickel-Plated in Bag Medium drawbolt : Product type: Catches • Type: Drawbolt catches • Material: Steel • Surface: nickel plated • Mounting hole diameter: 4.2 mm...

€3.99 *

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Adam Hall Hardware 172572P Butterfly groß gekröpft 9 mm tief

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

Butterfly Latch V3 large cranked 9 mm deep padlockable 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...

€13.98 *

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Adam Hall Hardware 1725 KEEP Schließe für Butterfly-Verschluss 17250 C

Adam Hall Hardware 1725 KEEP - Keeper for butterfly latch 17250 C

Keeper for butterfly latch 17250 C : Product type: Catch Accessories • Material: Steel • Weight: 0,026 kg •

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€0.55 *

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

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

Butterfly Latch medium half cranked 12 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...

€10.20 *

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Adam Hall Hardware 17284 P Butterfly Verschluss mittel gekröpft 12mm

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

Butterfly Latch medium cranked 12 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 it...

€10.20 *

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Adam Hall Hardware 17285 P Butterfly Verschluss mittel ungekröpft 9 mm

Adam Hall Hardware 17285 P - Butterfly Latch medium non cranked 9 mm deep padlockable

Butterfly Latch medium non cranked 9 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...

€10.20 *

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Adam Hall Hardware 88001 M Beschriftungsschild Kunststoff weiß magnetisch

Adam Hall Hardware 88001 M - Tour Label plastic white magnetic 177x127mm

Tour Label plastic white magnetic 177x127mm Magnetic Tour Label, white, laminated with protective clear foil surface. Can be easily cleaned and re-used without print fade. : Product type:...

€7.32 *

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Adam Hall Hardware 5927 M8 AH 8er Set Schrauben M6 x 12 mm

Adam Hall 19" Parts 5927 M8 AH - Bag of 8 M6 x 12 mm Screw with Cage Nut and Washer

Bag of 8 M6 x 12 mm Screw with Cage Nut and Washer : Product type: Fittings • Product type: Fittings • Product type: Fittings • Product type: Fittings • Type: Screws...

€7.18 *

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Adam Hall Hardware 6102 ALT Aluminium-Hybrid-Schließprofil für 7 mm

Adam Hall Hardware 6102 ALT - Aluminium Hybrid Lid Location for 7 mm Material without Chamfer

Aluminium Hybrid Lid Location for 7 mm Material without Chamfer : Product type Profiles • Type Lid Locations • Material Aluminium • Surface nature • Color nature • Length...

€3.49 *

Content: 1 m

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Bralo 55944824 Blindniete für weiche Materialien 4,8 x 24 mm

Bralo 55944824 - Pop-Rivet Truss-Head 4.8 x 24 mm

Pop-Rivet Truss-Head 4.8 x 24 mm Single-sided application (blind rivet) • Blind rivets can be inserted from both sides • Can be used to connect soft and brittle materials, among other...

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€0.11 * €0.08 *

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Adam Hall Hardware 88000 Beschriftungsschild Kunststoff weiß 130 x 85 mm

Adam Hall Hardware 88000 - Tour Label plastic white self-adhesive 130 x 85mm

Tour Label plastic white self-adhesive 130 x 85mm Self Adhesive Tour Label, white, laminated with protective clear foil surface. Can be easily cleaned and re-used without print fade. : Product...

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€4.21 *

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Adam Hall Hardware 88002 Beschriftungsschild Kunststoff weiß 220 x 150mm

Adam Hall Hardware 88002 - Tour Label plastic white self-adhesive 220 x 150mm

Tour Label plastic white self-adhesive 220 x 150mm Self Adhesive Tour Label, white, laminated with protective clear foil surface. Can be easily cleaned and re-used without print fade. : Product...

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€5.53 *

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Adam Hall Hardware 3411 Gehäuse-Griff Stahl

Adam Hall Hardware 3411 - Shell Type handle steel

Shell Type handle steel 1,5 mm steel, zinc plated • Small recessed shell type handle, same height as 2U butterfly 1702, therefore perfectly to be used on 2U 19” cases or other...

€2.42 *

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Adam Hall Hardware 3411 P Gehäuse-Griff Kunststoff

Adam Hall Hardware 3411 P - Shell Type handle plastic

Shell Type handle plastic Small recessed shell type handle, same height as 2U butterfly 1702, therefore perfectly to be used on 2U 19” cases or other applications where a small and simple...

€1.49 *

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Adam Hall Hardware 88000 D Einbauschale für Tour-Label

Adam Hall Hardware 88000 D - Recessed Dish for 88000 Tour Label

Recessed Dish for 88000 Tour Label This zinc plated tour label dish is made of steel and 7 mm deep. It is suitable for 130 x 85 mm labels. : Product type: Recessed Dishes • Dish material:...

€5.16 *

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Adam Hall Hardware 88002 D Einbauschale für Tour-Label

Adam Hall Hardware 88002 D - Recessed Dish for 88002 Tour Label

Recessed Dish for 88002 Tour Label This zinc plated tour label dish is made of steel and 7 mm deep. It is suitable for 220 x 150 mm labels. : Product type: Recessed Dishes • Dish material:...

€8.24 *

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Adam Hall Hardware 88005 D Einbauschale Stahl verzinkt 332 x 232 mm

Adam Hall Hardware 88005 D - Tour Label Dish

This zinc plated tour label dish is made of steel and 8,8 mm deep. It is suitable for 290x190mmlabels. : Product type: Recessed Dishes • Type: label dish • Dish material: Steel...

€12.22 *

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Adam Hall Hardware 6250 M Auszugprofil Aluminium männlich

Adam Hall Hardware 6250 M - Aluminium sliding profile male

Aluminium sliding profile male The profiles 6250M and 6250F can be used to facilitate simple drawer extensions. : Product type: Profiles • Material: Aluminium • Surface: nature...

€3.66 *

Content: 1 m

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Adam Hall Hardware 5725 B Ösenbefestigungsscheibe. Alu-Zurrpunkt, Schwarz

Adam Hall Hardware 5725 B - Flying Plate, Aluminium Lashing Point, Black

Flying Plate, Aluminium Lashing Point, Black Direct tensile load-bearing capacity of up to 500 daN depending on the lashing belt type, airline rail and surface attachment • Equipped with a...

€8.23 *

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Adam Hall Hardware 17300 Rammschutz für große und mittlere Butterfly

Adam Hall Hardware 17300 - Protection Dish for large and medium butterfly catches

Protection Dish for large and medium butterfly catches Surface mount protection dish to be used for butterfly catches 17290C and 17250C • 1.5 mm steel, zinc plated • : Product type: Catch...

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€2.33 * €1.67 *

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Adam Hall Hardware 2651 Scharnier 75mm x 2mm

Adam Hall Hardware 2651 - Hinge 75mm x 2mm

Hinge 75mm x 2mm Large strong strap hinge for building crates. : Product type: Hinges and Lidstays • Type: hinge • Material: Steel • Surface: galvanized • Material thickness:...

€1.75 *

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Adam Hall Hardware 34081 BLK Gefederter Klappgriff Medium

Adam Hall Hardware 34081 BLK - Medium Spring Loaded Flip Handle

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

€6.53 *

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Adam Hall Hardware 6225 - Abschlussprofil mit 5mm Radius f. 10mm Material

Adam Hall Hardware 6225 - Aluminium end profile with 5 mm Radius for 10 mm Material

Aluminium end profile with 5 mm Radius for 10 mm Material Aluminium Capping Channel : Product type: Profiles • Type: Capping Profile • Material: Aluminium • Surface: nature...

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€4.92 *

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