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 19" Parts 872205 STLV - 19" 0,5 HE Stahl U-Rackblende mit vertikalen Lüftungsschlitzen

Adam Hall 19" Parts 872205 STLV - 19" 0.5 U Steel U-Rack Panel with Vertical Ventilation Slots

19" 0.5 U Steel U-Rack Panel with Vertical Ventilation Slots U-rack cover with vertical ventilation slots : Product type: 19" Rack Panels • Material: Steel • Surface: Powder...

€5.27 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts 876 TL - 19 Zoll L-Tragschienen / Tragewinkel ( 2 Stück )

Adam Hall 19" Parts 876 TL - 19-inch L-rails / mounting brackets (2 pieces)

: Product type: 19" Rack Strips • Material: Steel • Material thickness: 1.5 mm • Surface: Powder coated • Length: 450 mm • Max. load: 37.5 kg • Weight: 0,838 kg...

€14.51 *

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Delivery time: approx. 1 week

Adam Hall Hardware 2642 - L-Scharnier Stahl verzinkt klein

Adam Hall Hardware 2642 - L-shaped Hinge Small Steel Galvanized

L-shaped Hinge Small Steel Galvanized In principle the combination of 4041 and 2602. But the L-bracket is slightly higher as 4041 to cover the gap between lid location and case angle. : Product...

€1.68 *

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Delivery time: approx. 1 week

Adam Hall Hardware 372251 - Lenkrolle 100 mm Heavy Duty mit grünem Rad

Adam Hall Hardware 372251 - Swivel Castor 100 mm Heavy Duty with Green Wheel

Swivel Castor 100 mm Heavy Duty with Green Wheel Double ball race on swivel • Replaceable bolt on wheel • Additional dust cap • Housing 2.5 mm zinc plated steel • Safe running...

€12.20 *

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Delivery time: approx. 1 week

Adam Hall Hardware 372291 - Lenkrolle 100 mm Heavy Duty mit grünem Rad und Feststeller

Adam Hall Hardware 372291 - Swivel Castor 100 mm Heavy Duty with green Wheel and Brake

Swivel Castor 100 mm Heavy Duty with green Wheel and Brake Double ball race on swivel • Brake for wheel and swivel • Replaceable bolt on wheel • Additional dust cap • Housing...

€15.08 *

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Delivery time: approx. 1 week

Adam Hall Hardware 56515 - Unterlegscheiben 5,0 x 15 mm, Stahl verzinkt

Adam Hall Hardware 56515 - Washers 5.0 x 15 mm, Steel Zinc plated

Washers 5.0 x 15 mm, Steel Zinc plated Galvanized 15 mm washer with an inner diameter of 5 mm. Also ideal for use in conjunction with rivets for rear reinforcement. : Product type: Fittings...

Express delivery possible

€0.03 *

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Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 87085 BLK - Stahl Einbauplatte für 2 x powerCON TRUE1 Buchsen, schwarz

Adam Hall Hardware 87085 BLK - Steel Mounting Plate for 2 x powerCON TRUE1 Sockets, black

Steel Mounting Plate for 2 x powerCON TRUE1 Sockets, black Mounting plate for 2 powerCON TRUE1 sockets Cutout: 115 x 67 mm : Product type: Recessed Dishes • Dish material: Steel • Dish...

€1.89 *

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Adam Hall Hardware 87999 - 2 x schwarze Befestigungsklammern 95 x 40 mm für Rohre, Beine etc.

Adam Hall Hardware 87999 - 2 x black Fixing Clamps 95 x 40 mm for Tubes, Legs, etc.

2 x black Fixing Clamps 95 x 40 mm for Tubes, Legs, etc. Fixing clamps made of black spring steel for fixing tubes, legs, etc.To protect the tubes against scratching, a felt is attached inside. :...

€8.94 *

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Delivery time: approx. 1 week

Delivery time: approx. 1 week

Bralo 55914817 BLK - Blindniete Aluminium "MULTIGRIP" 4,8 x 16,5 mm schwarz

Bralo 55914817 BLK - Pop-rivet aluminium "MULTIGRIP" 4.8 x 16.5 mm, Black

Pop-rivet aluminium "MULTIGRIP" 4.8 x 16.5 mm, Black Multi-range properties (Multi Grip) can be used with a wide range of clamping areas. • Single-sided application (blind rivet)...

Express delivery possible

€0.08 *

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Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Tente 37033 - Lenkrolle 100 mm mit blauem Rad

Tente 37033 - Swivel Castor 100 mm with blue Wheel

Swivel Castor 100 mm with blue Wheel Original 100% Made in Germany! Swivel castor, steel frame, zinc-plated with blue passivation, double ball race swivel, bolted wheel axle, swivel bearing...

€15.07 *

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Delivery time: approx. 1 week

Tente 37035 - Lenkrolle 125 mm mit blauem Rad

Tente 37035 - Swivel Castor 125 mm with blue Wheel

Swivel Castor 125 mm with blue Wheel Original 100% Made in Germany! Swivel castor, steel frame, zinc-plated with blue passivation, double ball race swivel, bolted wheel axle, swivel bearing...

€25.16 *

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Delivery time: approx. 1 week

Tente 37036 - Lenkrolle 125 mm mit blauem Rad und Feststeller

Tente 37036 - Swivel Castor 125 mm with blue Wheel and Brake

Swivel Castor 125 mm with blue Wheel and Brake Original 100% Made in Germany! Swivel castor with double-action brake lock, steel frame, zinc-plated with blue passivation, double ball race swivel,...

€32.52 *

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Delivery time: approx. 1 week

Delivery time: approx. 1 week

Tente 37037 - Lenkrolle 100 mm mit petrolfarbigem Rad und Richtungsselbststeller

Tente 37037 - Swivel Castor 100 mm with petrol wheel and directional self-setting feature

Swivel Castor 100 mm with petrol wheel and directional self-setting feature Exclusive Version with high load Capacity and qualitative Longevity • Original 100% Made in Germany! • Swivel...

€26.58 *

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Delivery time: approx. 1 week

Tente 37038 - Lenkrolle 100 mm mit petrolfarbigem Rad, Feststeller und Richtungsselbststeller

Tente 37038 - Swivel Castor 100 mm with petrol Wheel, brake and directional self-setting feature

Swivel Castor 100 mm with petrol Wheel, brake and directional self-setting feature Exclusive Version with high load Capacity and qualitative Longevity • Original 100% Made in Germany!...

€28.82 *

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Delivery time: approx. 1 week

OMNITRONIC Front Panel ZL-19 bl 1U

(19") 48.3 cm rack installation 1 U • Material: Steel, 1 mm • Color: Black • Mounting height: Approx. 4.5 cm (1 U) • Housing design: (19") 48.3 cm rack installation 1...

€4.50 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

OMNITRONIC Front Panel Z-19 bl 2U

(19") 48.3 cm rack installation 2 U • Material: Steel, 1 mm • Mounting height: Approx. 9 cm (2 U) • Housing design: (19") 48.3 cm rack installation 2 U • Weight: 0,36...

€6.50 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Adam Hall Hardware 37300 S - Eckeinbaurolle 100 mm in Alu-Druckgussgehäuse

Adam Hall Hardware 37300 S - Corner installation roller 100 mm in die-cast aluminium housing

Corner installation roller 100 mm in die-cast aluminium housing Very quiet running due to high-quality rubber tread of the blue roller • 150 kg load capacity per set (2 castors)...

€17.85 *

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Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 87365 - Auszugschienen Set, Stahl 350 mm, max. 45 kg

Adam Hall Hardware 87365 - Pull-Out Rail Set, Steel 350 mm, max. 45 kg

Pull-Out Rail Set, Steel 350 mm, max. 45 kg Full-extension runner • with quick release • Precision full extension. Very light, laterally stable running. With quick release inner rail for...

€19.20 *

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Delivery time: approx. 1 week

Adam Hall 19" Parts KYOTO FOAM - KYOTO FOAM Inlay für 2HE Rackschubladen zuschneidbar

Adam Hall 19" Parts KYOTO FOAM - KYOTO FOAM Inlay for 2U rack drawers can be cut to size

KYOTO FOAM Inlay for 2U rack drawers can be cut to size Firm, dimensionally stable foam • Constructed in 5 bonded layers • Can be removed layer by layer • Knife included...

€19.90 *

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Delivery time: approx. 1 week

Adam Hall Hardware 2604 - Doppelscharnierband

Adam Hall Hardware 2604 - Double hinge

Double hinge, like double hinge 2600, but in 180.3 cm length for cutting to length. : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: galvanized...

€32.00 *

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Delivery time: approx. 1 week

Adam Hall Hardware 2645 - Scharnier für 6145

Adam Hall Hardware 2645 - Hinge for 6145

Hinge for 6145 With this hinge, hinged lids can be realised with our flat lid system. : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: galvanized...

€3.76 *

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Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 38095 - Steckplatte für Adam Hall-Rollen

Adam Hall Hardware 38095 - Plug-in plate for Adam Hall castors

Plug-in plate for Adam Hall castors 372081, 372091, 372151, 372191, 372251, 372291, 372151BLK, 372191BLK • : Product type: Castor Accessories • Material: Aluminium • Width: 112 mm...

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€10.39 *

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Express delivery possible

Availability:

Low stock; Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 4994 - Kleine Lüftungsschale, rund

Adam Hall Hardware 4994 - Small ventilation dish, round

Small ventilation dish, round Small ventilation tray, round • : Product type: Recessed Dishes • Dish material: Steel • Dish surface: galvanized • Dish colour: silver • Dish...

€3.12 *

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Delivery time: approx. 1 week

Adam Hall Hardware 87720 - Schwingmetallpuffer rund, hart

Adam Hall Hardware 87720 - Vibrating metal buffers round, hard

Vibrating metal buffers round, hard Round oscillating metal buffer with two M6 female threads for suspension of our shock-mount frame : Product type: Bumper • Hardness range: 70 Shore Shore...

€3.36 *

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Delivery time: approx. 1 week

Delivery time: approx. 1 week