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 3443 BLK - Klappgriff Stahl, schwarz

Adam Hall Hardware 3443 BLK - Sprung Handle, Steel, black

Sprung Handle, Steel, black Sprung handle with black grip : Product type: Handles • Type: Folding Handles • Mounting plate material: Steel • Surface of mounting plate: galvanized...

€5.04 *

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Adam Hall 19" Parts 872005 VR
19" U-Lüftungsblende 0,5 HE, Rundlochung

Adam Hall 19" Parts 872005 VR - 19" U-shaped Ventilation Panel, 0.5 U, Round Holes

19" U-shaped Ventilation Panel, 0.5 U, Round Holes U-shaped ventilation panel with round holes Air passage 45 cm² • : Product type: 19" Rack Panels • Color: Black...

€5.25 *

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Adam Hall 19" Parts 872205 LBL
19" U-Rackblende 0,5 HE,

Adam Hall 19" Parts 872205 LBL - 19" U-Rack Panel 0.5 U, with Plastic Labeling Strips

19" U-Rack Panel 0.5 U, with Plastic Labeling Strips If you want to label your rack panel for a better overview, the 872205 LBL is the safe choice. The front surface is intended for labeling....

€5.37 *

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Adam Hall Hardware 37601 S - Corner Castor with 48 mm Wheel in Aluminium Die-Cast Housing, cranked

Corner Castor with 48 mm Wheel in Aluminium Die-Cast Housing, cranked 48 mm wheel PU / PP, Shore A hardness 82° • With ball bearings • Die-cast aluminium housing • Mounting holes...

€12.48 *

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Adam Hall Hardware 4058 ZP - Flat Corner Large Stepped, Galvanized

Flat Corner Large Stepped, Galvanized : Product type: Corners • Type: flat corner • Material: Steel • Surface: galvanized • Color: silver • Material thickness: 1.2 mm...

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€1.24 *

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Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 40433 - L-Corner 60 mm x 50 mm Angled for 6111, Galvanized

L-Corner 60 mm x 50 mm Angled for 6111, Galvanized Corner Brace : Product type: Corner Braces • Material: Steel • Surface: galvanized • Color: silver • Material thickness: 1.5...

€1.03 *

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Adam Hall Hardware 27096 H - Lid Stay Medium half cranked with Hinge and Click-Stop Function

Lid Stay Medium half cranked with Hinge and Click-Stop Function : Product type: Hinges and Lidstays • Type: lid stay • Dish material: Steel • Dish surface: galvanized • Dish...

€6.86 *

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Adam Hall Hardware 2643 - Hinge Galvanized Steel, 48 mm Wide

Hinge Galvanized Steel, 48 mm Wide Small L-hinge with a hinge length of 48 mm. : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: galvanized...

€2.03 *

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Adam Hall Hardware 4003 - Small Corner with integrated Corner Brace

Small Corner with integrated Corner Brace : Product type: Corners • Type: flat corner • Material: Steel • Surface: galvanized • Color: silver • Material thickness: 1 mm...

€0.94 *

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Adam Hall Hardware 1907 M10 AH - 10 x Drawbolt Lock small, lockable, Nickel-plated in Bag Packaging

10 x Drawbolt Lock small, lockable, Nickel-plated in Bag Packaging Large surface-mounted lock in nickel-plated design with locking function in pack of 10 : Product type: Catches • Material:...

€78.57 *

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Adam Hall Hardware 40434 - Corner Brace 37 x 19 mm, Steel Galvanized

Corner Brace 37 x 19 mm, Steel Galvanized Galvanized steel L-shaped corner measuring 37 x 19 mm. : Product type: Corner Braces • Type: flat corner • Material: Steel • Surface:...

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€0.39 *

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Availability:

Delivery time: 1-3 days

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Adam Hall 19" Parts 87223 VH - 19" U-Shaped Ventilation Panel with Vertical Slots, 3 U

19" U-Shaped Ventilation Panel with Vertical Slots, 3 U : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 3 U...

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€16.98 *

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Delivery time: 1-3 days

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Adam Hall 19" Parts 87224 VH - 19" U-Shaped Ventilation Panel with Vertical Slots, 4 U

19" U-Shaped Ventilation Panel with Vertical Slots, 4 U : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 4 U...

€27.56 *

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IMG STAGELINE RM/MXR-60 482 mm (19") mounting bracket set

482 mm (19") mounting bracket set For rack installation of 6-channel audio mixer MXR-60 • 2 mounting brackets • Black lacquered metal version • : Description: mounting bracket...

€19.00 *

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Delivery time: 3-5 days

Delivery time: 3-5 days

IMG STAGELINE RM/MXR-80 482 mm (19") mounting bracket set

482 mm (19") mounting bracket set For rack installation of 8-channel audio mixer MXR-80 • 2 mounting brackets • Black lacquered metal version • : Description: mounting bracket...

€19.00 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Showgear Schiebefach für FSM/FSG/WMF/WMH Serie

1U Sliding Rack Mount Shelf For Showgear FSM/FSG/WMF/WMH series

For Showgear FSM/FSG/WMF/WMH series • Provides good ventilation • 1U • Black • Cage nut & screws included • The Showgear Sliding Rack Mount Shelf is a 1U high...

€28.90 *

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Delivery time: 3-5 days

Delivery time: 3-5 days

Adam Hall Hardware 49051 BLK - Runde Stahl Einbauplatte für 1x universal D-Type Buchse, schwarz

Adam Hall Hardware 49051 BLK - Round Steel Mounting Plate for 1 x Universal D-Type Socket, black

Round Steel Mounting Plate for 1 x Universal D-Type Socket, black Stamping for universal D-Type socket • Cut-out: Ø 50 mm • : Product type: Recessed Dishes • Dish material:...

€1.68 *

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Adam Hall Hardware 87081 BLK - Stahl Einbauplatte für 1 x universal D-Type Buchse, schwarz

Adam Hall Hardware 87081 BLK - Steel Mounting Plate for 1 x Universal D-Type Socket, black

Steel Mounting Plate for 1 x Universal D-Type Socket, black Recess for 1 x universal D-type socket • Cut-out size 67 x 67 mm • : Product type: Recessed Dishes • Dish material: Steel...

€1.31 *

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NEUTRIK Dummy plate to cover D-shape cut outs

: Brand Connector 1: Neutrik • Material: Plastic • Colour: Black •

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€1.31 *

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Showgear 19 Inch Blind Panel Black 2 mm starke Metallplatte - schwarz

SHOWGEAR 19 Inch Blind Panel Black 0.5U

19" blind plate • Available in 1/2U, 1U, 2U, 3U and 4U • Black • Metal • The Showgear 19" Blind Plate is available in different heights (1/2U-4U). It is made out of 2...

€4.35 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Showgear 19 Inch Ventilation Panel Black 2 mm starke Metallplatte - schwarz

SHOWGEAR 19 Inch Ventilation Panel Black 0.5U

19" ventilation panel • Available in different heights (1/2-2U) • Black • Metal • The Showgear 19" Ventilation Panel is available in 1/2U, 1U and 2U height. It is made...

€5.15 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Showgear 4-way, 1U Fan Unit Temperature Controlled Für 19"-Rack oder Schrank

SHOWGEAR 4-way, 1U Fan Unit Temperature Controlled For 19" rack or cabinet

4-way fan unit • Temperature controlled • 1U height • Suitable for 19" rack or cabinet • Including mounting screws, thermostat and power cable • The Showgear 2-Way 1U...

Express delivery possible

€139.00 *

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

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall 19" Parts 1658 - Verschluss Kunststoff für Rackschubladen

Adam Hall 19" Parts 1658 - Latch for Rack Door Plastic

Latch for Rack Door Plastic Latch for Rack doors : Product type: Catches • Type: Lever Latches • Material: Plastic • Weight: 0,015 kg •

€2.87 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 565 XTOOL - Werkzeug für Käfigmuttern Einbau & Ausbau

Adam Hall 19" Parts 565 XTOOL - Tool for Installing and removing Cage Nuts

Tool for Installing and removing Cage Nuts This tool is an indispensable aid for technicians and installers who want to install or remove captive nuts, such as in 19" (48 cm) rack rails....

€12.27 *

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Delivery time: approx. 1 week