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 54M8X25 - Sperrzahn Schraube M8x25 mm, Stahl verzinkt, selbstsichernd

Adam Hall Hardware 54M8X25 - Screw M8 x 25mm with Gear Rim, Galvanized Steel, self-securing

Screw M8 x 25mm with Gear Rim, Galvanized Steel, self-securing No further use of washers or lock washers necessary thanks to the integrated toothed ring. : Product type: Fittings • Type:...

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€0.23 *

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Adam Hall Hardware 56 M6 NUT - Sperrzahn Mutter M6,Stahl verzinkt,selbstsichernd

Adam Hall Hardware 56 M6 NUT - Nut M6 with Gear Rim, Galvanized Steel, self-locking

Nut M6 with Gear Rim, Galvanized Steel, self-locking Thanks to the integrated toothed ring, no additional washers or lock washers are required. : Product type: Fittings • Type: Locking tooth...

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€0.16 *

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Adam Hall Hardware 56 M8 NUT - Sperrzahn Mutter M8,Stahl verzinkt,selbstsichernd

Adam Hall Hardware 56 M8 NUT - Nut M8 with Gear Rim, Galvanized Steel, self-locking

Nut M8 with Gear Rim, Galvanized Steel, self-locking Thanks to the integrated toothed ring, no additional washers or lock washers are required. : Product type: Fittings • Type: Locking tooth...

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€0.20 *

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Adam Hall Hardware 6109 BLK - Aluwinkel Kantenschutz 22 x 22mm, schwarz eloxiert

Adam Hall Hardware 6109 BLK - Aluminium angle edge protector 22 x 22mm, black anodised

Aluminium bracket edge protection 22 x 22mm, black anodized Price per meter, delivery in 2 meter lengths : Product type: Profiles • Type: Edge protection • Material: Aluminum...

€12.09 *

Content: 1 m

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Adam Hall Hardware 6200 BLK - Aluminium Kappe für 7 mm Trennwände, schwarz

Adam Hall Hardware 6200 BLK - Aluminium Capping Channel for 7 mm Dividing Wall, black

Aluminium Capping Channel for 7 mm Dividing Wall, black : General Material: Aluminium • Coating: Anodised • Colour: Black • Dimensions & weight Length: 4,000 mm • Width: 1.5...

€5.84 *

Content: 1 m

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Adam Hall Hardware 6240 BLK - Aluminium Kappe für 9,5 mm Trennwände, schwarz

Adam Hall Hardware 6240 BLK - Aluminium Capping Channel for 9.5 mm Dividing Wall, black

Aluminium Capping Channel for 9.5 mm Dividing Wall, black Aluminium capping channel for 9.5 mm partition walls : General Material: Aluminium • Coating: Anodised • Colour: Black...

€12.36 *

Content: 1 m

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Adam Hall Hardware 87952 - Bar Code Scan Fenster in Stahl Einbauschschale 114 x x166mm

Adam Hall Hardware 87952 - Bar Code Scan Window Steel 114 x x166mm

Bar Code Scan Window Steel 114 x x166mm Bar code scan window, allowing content with bar code to be scanned without removing from case. : Product type: Recessed Dishes • Dish material: Steel...

€14.84 *

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Adam Hall Hardware 88001 D BLK - Einbauschale für Beschriftungsschild 88001, schwarz

Adam Hall Hardware 88001 D BLK - Dish for 88001 Tour Label, black

Dish for 88001 Tour Label, black Black flightcase mounting dish for inscription label 88001 • Galvanised steel • Dish dimensions (H x W x D): 170 mm x 220 mm x 6 mm • : Product type:...

€8.90 *

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Adam Hall Hardware 88001 M BLUE - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, blau

Adam Hall Hardware 88001 M BLUE - Plastic tour label, magnetic 177 x127 mm, blue

Plastic tour label, magnetic 177 x127 mm, blue Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for individual...

€12.66 *

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Adam Hall Hardware 88001 M BLACK - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, schwarz

Adam Hall Hardware 88001 M BLACK - Plastic tour label, magnetic 177 x127 mm, black

Plastic tour label, magnetic 177 x127 mm, black Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for individual...

€12.66 *

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Adam Hall Hardware 88001 M BROWN - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, braun

Adam Hall Hardware 88001 M BROWN - Plastic tour label, magnetic 177 x127 mm, brown

Plastic tour label, magnetic 177 x127 mm, brown Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for individual...

€12.66 *

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Adam Hall Hardware 88001 M GREEN - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, grün

Adam Hall Hardware 88001 M GREEN - Plastic tour label, magnetic 177 x127 mm, green

Plastic tour label, magnetic 177 x127 mm, green Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for individual...

€12.66 *

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Adam Hall Hardware 88001 M GREY - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, grau

Adam Hall Hardware 88001 M GREY - Plastic tour label, magnetic 177 x127 mm, grey

Plastic tour label, magnetic 177 x127 mm, grey Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for individual...

€12.66 *

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Adam Hall Hardware 88001 M ORANGE - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, orange

Adam Hall Hardware 88001 M ORANGE - Plastic tour label, magnetic 177 x127 mm, orange

Plastic tour label, magnetic 177 x127 mm, orange Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for...

€12.66 *

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Adam Hall Hardware 88001 M PURPLE - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, lila

Adam Hall Hardware 88001 M PURPLE - Plastic tour label, magnetic 177 x127 mm, purple

Plastic tour label, magnetic 177 x127 mm, purple Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for...

€12.66 *

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Adam Hall Hardware 88001 M RED - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, rot

Adam Hall Hardware 88001 M RED - Plastic tour label, magnetic 177 x127 mm, red

Plastic tour label, magnetic 177 x127 mm, red Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for individual...

€12.66 *

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Adam Hall Hardware 88001 M YELLOW - Beschriftungsschild Kunststoff, magnetisch 177 x127 mm, gelb

Adam Hall Hardware 88001 M YELLOW - Plastic tour label, magnetic 177 x127 mm, yellow

Plastic tour label, magnetic 177 x127 mm, yellow Magnetic back for easy replacement of the tour label • Label field is easy to clean and reusable • Further colours available for...

€12.66 *

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Bralo 55924806 BLK - Blindniete Flachkopf 4,8x6mm, Schwarz

Bralo 55924806 BLK - Blind Rivet Flat Head 4.8x6mm, Black

Blind Rivet Flat Head 4.8x6mm, Black Only one-sided machining necessary (blind rivet) • Covering a large clamping range • Different materials can be joined such as metal on metal,...

€0.13 *

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Bralo 55924808 BLK - Blindniete Standard 4,8 x 8,0, schwarz

Bralo 55924808 BLK - Blind rivet standard 4.8 x 8.0, black

Blind rivet standard 4.8 x 8.0, black Only one-sided processing is required (blind rivet) • Covers a large clamping area • Can be used to connect different materials such as metal on...

€0.14 *

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Bralo 55964814 - Gerillter Blindniet aus Aluminium / Stahl 4,8 x14 mm

Bralo 55964814 - Grooved blind rivet made of aluminium / steel 4.8 x14 mm

Grooved blind rivet made of aluminium / steel 4.8 x14 mm Can only be processed from one side (blind rivet principle) • Secure connection in blind holes • Numerous grooves provide the...

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€0.10 *

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Defender 866 XPF 8 - 8er Set Anti-Rutsch Füße 27mm XPRESS

Defender 866 XPF 8 - Set of 8 anti-slip feet 27mm XPRESS

Set of 8 anti-slip feet 27mm XPRESS Material made of soft and durable TPE plastic • Special grip structure for a variety of surfaces • Easy and tool-free installation • Firm and...

€11.60 *

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Defender 866 XPF 80 - 80er Set Anti-Rutsch Füße 27mm XPRESS

Defender 866 XPF 80 - Set of 80 anti-slip feet 27mm XPRESS

Set of 80 anti-slip feet 27mm XPRESS Material made of soft and durable TPE plastic • Special grip structure for a variety of surfaces • Easy and tool-free installation • Firm and...

€80.25 *

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Adam Hall Hardware 1907 KEY - Schlüssel für Schnappschloss 1907

Adam Hall Hardware 1907 KEY - Key for Drawbolt 1907

Key for Drawbolt 1907 : Weight: 0,01 kg •

€1.30 *

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Adam Hall Hardware 6224 - Alu Kappenprofil mit 4 mm Radius für 7 mm Material

Adam Hall Hardware 6224 - Aluminium capping with 4 mm radius for 7 mm material

Aluminium capping with 4 mm radius for 7 mm material Aluminium cap profile, particularly suitable as an edge closure for cases and racks that are built without a lid. : Product type: Profiles...

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€3.52 *

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