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 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 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

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...

Express delivery possible

€0.10 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

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 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

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 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

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 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

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...

Express delivery possible

€4.46 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Details

Adam Hall Hardware 019305 B - Plastazote® (LD29) 2000 x 1200 x 5 mm

Plastazote® (LD29) 2000 x 1200 x 5 mm Length: 2000 mm • Width: 1200 mm • Thickness: 5 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 5 mm. The width of 1200 mm...

€21.28 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019305SA B - Plastazote (LD29) selbstklebend 2000 x 1200 x 5 mm

Adam Hall Hardware 019305SA B - Plastazote (LD29) self-adhesive 2000 x 1200 x 5 mm

Plastazote (LD29) self-adhesive 2000 x 1200 x 5 mm Self-adhesive • Length: 2000 mm • Width: 1200 mm • Thickness: 5 mm • Self-adhesive PE foam "Plastazote" (LD29), 2000...

€38.06 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 0193100 B - Plastazote® (LD29) 2000 x 1200 x 100 mm

Plastazote® (LD29) 2000 x 1200 x 100 mm Length: 2000 mm • Width: 1200 mm • Thickness: 100 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 100 mm. The width of 1200 mm...

€345.68 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019310 B - Plastazote® (LD29) 2000 x 1200 x 10 mm

Plastazote® (LD29) 2000 x 1200 x 10 mm Length: 2000 mm • Width: 1200 mm • Thickness: 10 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 10 mm. The width of 1200 mm...

€34.38 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019310SA B - Plastazote (LD29) selbstklebend 2000 x 1200 x 10 mm

Adam Hall Hardware 019310SA B - Plastazote (LD29) self-adhesive 2000 x 1200 x 10 mm

Plastazote (LD29) self-adhesive 2000 x 1200 x 10 mm Self-adhesive • Length: 2000 mm • Width: 1200 mm • Thickness: 10 mm • Self-adhesive PE foam "Plastazote" (LD29),...

€54.88 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019315 B - Plastazote® (LD29) 2000 x 1200 x 15 mm

Plastazote® (LD29) 2000 x 1200 x 15 mm Length: 2000 mm • Width: 1200 mm • Thickness: 15 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 15 mm. The width of 1200 mm...

€50.87 *

incl. tax, plus shipping costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019315SA B - Plastazote (LD29) selbstklebend 2000 x 1200 x 15 mm

Adam Hall Hardware 019315SA B - Plastazote (LD29) self-adhesive 2000 x 1200 x 15 mm

Plastazote (LD29) self-adhesive 2000 x 1200 x 15 mm Self-adhesive • Length: 2000 mm • Width: 1200 mm • Thickness: 15 mm • Self-adhesive PE foam "Plastazote" (LD29),...

€71.82 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019320 B - Plastazote® (LD29) 2000 x 1200 x 20 mm

Plastazote® (LD29) 2000 x 1200 x 20 mm Length: 2000 mm • Width: 1200 mm • Thickness: 20 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 20 mm. The width of 1200 mm...

€67.90 *

incl. tax, plus forwarding agency costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Bulky goods

Adam Hall Hardware 019320SA B - Plastazote (LD29) selbstklebend 2000 x 1200 x 20 mm

Adam Hall Hardware 019320SA B - Plastazote (LD29) self-adhesive 2000 x 1200 x 20 mm

Plastazote (LD29) self-adhesive 2000 x 1200 x 20 mm Self-adhesive • Length: 2000 mm • Width: 1200 mm • Thickness: 20 mm • Self-adhesive PE foam "Plastazote" (LD29),...

€88.88 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019330 B - Plastazote® (LD29) 2000 x 1200 x 30 mm

Plastazote® (LD29) 2000 x 1200 x 30 mm Length: 2000 mm • Width: 1200 mm • Thickness: 30 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 30 mm. The width of 1200 mm...

€102.09 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019330SA B - Plastazote (LD29) selbstklebend 2000 x 1200 x 30 mm

Adam Hall Hardware 019330SA B - Plastazote (LD29) self-adhesive 2000 x 1200 x 30 mm

Plastazote (LD29) self-adhesive 2000 x 1200 x 30 mm Self-adhesive • Length: 2000 mm • Width: 1200 mm • Thickness: 30 mm • Self-adhesive PE foam "Plastazote" (LD29),...

€123.09 *

incl. tax, plus forwarding agency costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Bulky goods

Adam Hall Hardware 019340 B - Plastazote® (LD29) 2000 x 1200 x 40 mm

Plastazote® (LD29) 2000 x 1200 x 40 mm Length: 2000 mm • Width: 1200 mm • Thickness: 40 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 40 mm. The width of 1200 mm...

€136.45 *

incl. tax, plus forwarding agency costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Bulky goods

Adam Hall Hardware 019340SA B - Plastazote (LD29) selbstklebend 2000 x 1200 x 40 mm

Adam Hall Hardware 019340SA B - Plastazote (LD29) self-adhesive 2000 x 1200 x 40 mm

Plastazote (LD29) self-adhesive 2000 x 1200 x 40 mm Self-adhesive • Length: 2000 mm • Width: 1200 mm • Thickness: 40 mm • Self-adhesive PE foam "Plastazote" (LD29),...

€157.45 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019350 B - Plastazote® (LD29) 2000 x 1200 x 50 mm

Plastazote® (LD29) 2000 x 1200 x 50 mm Length: 2000 mm • Width: 1200 mm • Thickness: 50 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 50 mm. The width of 1200 mm...

€170.92 *

incl. tax, plus forwarding agency costs

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Bulky goods

Adam Hall Hardware 019350SA B - Plastazote (LD29) selbstklebend 2000 x 1200 x 50 mm

Adam Hall Hardware 019350SA B - Plastazote (LD29) self-adhesive 2000 x 1200 x 50 mm

Plastazote (LD29) self-adhesive 2000 x 1200 x 50 mm Self-adhesive • Length: 2000 mm • Width: 1200 mm • Thickness: 50 mm • Self-adhesive PE foam "Plastazote" (LD29),...

€191.91 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019360 B - Plastazote® (LD29) 2000 x 1200 x 60 mm

Plastazote® (LD29) 2000 x 1200 x 60 mm Length: 2000 mm • Width: 1200 mm • Thickness: 60 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 60 mm. The width of 1200 mm...

€205.55 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019370 B - Plastazote® (LD29) 2000 x 1200 x 70 mm

Plastazote® (LD29) 2000 x 1200 x 70 mm Length: 2000 mm • Width: 1200 mm • Thickness: 70 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 70 mm. The width of 1200 mm...

€240.35 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week

Adam Hall Hardware 019380 B - Plastazote® (LD29) 2000 x 1200 x 80 mm

Plastazote® (LD29) 2000 x 1200 x 80 mm Length: 2000 mm • Width: 1200 mm • Thickness: 80 mm • PE foam "Plastazote" (LD29), 2000 x 1200 x 80 mm. The width of 1200 mm...

€275.33 *

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

Availability:

Near-term available
Delivery time: approx. 1 week

Delivery time: approx. 1 week