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 87991 PLATE - Befestigungsplatte für Tischbeine 87990 und 87991

Adam Hall Hardware 87991 PLATE - Mounting plate for table legs 87990 and 87991

Mounting plate for table legs 87990 and 87991 3 mm material thickness • Black powder-coated • M10 internal thread • Fixing plate made of 3 mm thick, powder-coated steel with M10...

€9.48 *

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Riggatec fixed castor 80mm BLUE WHEEL

Riggatec Blue Wheels fixed castor 80 mm – Sturdy transport castors for a wide range of applications Riggatec Blue Wheels offer a premium mobility solution with high load capacity and...

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€4.85 * €3.20 *

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Riggatec swivel castor 80mm BLUE WHEEL

Riggatec Blue Wheels Caster Wheel 80 mm – Sturdy transport casters for a wide range of applications Riggatec Blue Wheels offer a premium mobility solution with high load capacity and...

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€5.85 * €3.80 *

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Riggatec Lenkrolle 80mm BLUE WHEEL mit Bremse

Riggatec swivel castor 80mm BLUE WHEEL with brake

Riggatec Blue Wheels swivel castor with brake 80 mm – Sturdy transport castors for a wide range of applications Riggatec Blue Wheels offer a premium mobility solution with high load capacity...

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€6.95 * €4.60 *

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Riggatec fixed castor 100mm BLACK WHEEL

Riggatec Black Wheels fixed castor 100 mm – Sturdy transport castors for a wide range of applications Riggatec Black Wheels offer a first-class mobility solution with high load capacity and...

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€5.85 *

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Adam Hall 19" Parts RACK PAN 01 HALF - Halbe 19" U-Rackblende 1HE

Adam Hall 19" Parts RACK PAN 01 HALF - Half 19" U-shaped Rack Panel 1U

Half 19" U-shaped Rack Panel 1U Half 19" rack panel cover • Made of steel • Powder coated surface • For covering 1U blank space in a rack • Dimensions: 246,2mm x...

€3.46 *

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Adam Hall Cables 4 STAR CD CASTOR SET - Set aus 4 Lenkrollen für K4CD450 & K4CD650

Adam Hall Cables 4 STAR CD CASTOR SET - Set of 4 castors for K4CD450 & K4CD650

Set of 4 castors for K4CD450 & K4CD650 Castor set for 4 STAR CD 450 & 4 STAR CD 650 • Four swivel castors, two with parking brake • Castor diameter of 50 mm • Easy assembly:...

€17.30 *

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Adam Hall Hardware 4113 BLK - Kugelecke klein, dreischenklig, gestuft für 6109, schwarz

Adam Hall Hardware 4113 BLK - Ball corner small, three-legged, stepped for 6109, black

Ball corner small, three-legged, stepped for 6109, black Small three-legged ball corner with offset for 22 mm edge protectors, black galvanised. Fixing holes with 4.2 mm diameter. : General...

€2.24 *

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Adam Hall Hardware 4905 BLK - Einbaustapelschale, schwarz

Adam Hall Hardware 4905 BLK - Recessed stacking dish, black

Recessed stacking dish, black Black stacking dish made of galvanised steel for rubber feet with a diameter of 38 mm. The 51 g dish has a diameter of 80 mm and a depth of 10 mm. : General Material:...

€3.54 *

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Adam Hall Hardware 49630 - Kufe aus schwarzem Kunststoff, 30 cm

Adam Hall Hardware 49630 - Black plastic runner, 30 cm

Black plastic runner, 30 cm Robust ABS plastic runner • For riveting or screwing • For use as a sliding skid for cases • Robust runner made of black ABS plastic, 30 cm long. Ideal as...

€9.38 *

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Adam Hall Hardware 49645 - Kufe aus schwarzem Kunststoff, 45 cm

Adam Hall Hardware 49645 - Black plastic runner, 45 cm

Black plastic runner, 45 cm Robust ABS plastic runner • For riveting or screwing • For use as a sliding skid for cases • Robust runner made of black ABS plastic, 45 cm long. Ideal as...

€12.08 *

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Adam Hall Hardware 49660 - Kufe aus schwarzem Kunststoff, 60 cm

Adam Hall Hardware 49660 - Black plastic runner, 60 cm

Black plastic runner, 60 cm Robust ABS plastic runner • For riveting or screwing • For use as a sliding skid for cases • Robust runner made of black ABS plastic, 60 cm long. Ideal as...

€14.80 *

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Riggatec Lenkrolle mit runder Montageplatte 100mm BLACK WHEEL

Riggatec swivel castor with round mounting plate 100mm BLACK WHEEL

Riggatec Black Wheels Caster Wheel 100 mm – Sturdy transport casters for a wide range of applications Riggatec Black Wheels offer a first-class mobility solution with high load capacity and...

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€6.60 * €4.99 *

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Riggatec Lenkrolle mit Bremse und runder Montageplatte 100mm BLACK WHEEL

Riggatec swivel castor with brake and round mounting plate 100mm BLACK WHEEL

Riggatec Black Wheels Caster Wheel 100 mm – Sturdy transport casters for a wide range of applications Riggatec Black Wheels offer a first-class mobility solution with high load capacity and...

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€8.30 * €6.49 *

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Adam Hall Hardware 34041 BLK - Kantengriff, schwarz

Adam Hall Hardware 34041 BLK - Case edge handle, black

Case edge handle, black Black powder-coated • Fits over aluminium edge extrusions up to 35 mm • Special Adam Hall design for fitting into the side edge of large, heavy flight cases or...

€14.50 *

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LIFTING WHEEL WITH 80 MM ROTATING CASTOR

Lifting wheel with 80 mm rotating caster

Admiral Staging Heberad – The clever solution for stage transport Are you tired of heavy lifting and laborious transport of Stage elements and trusses? The Admiral Staging jacking device with...

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€169.00 *

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[International shipping costs]

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Adam Hall Hardware 1630 KEEP BLK - Aufbauschließe für 17302 BLK, Stahl, schwarz galvanisiert

Adam Hall Hardware 1630 KEEP BLK - Keeper plate for 17302 BLK, steel, black galvanised

Keeper plate for 17302 BLK, steel, black galvanised Suitable for the Adam Hall 17302 BLK overlatch butterfly latch • Black galvanized steel – robust, corrosion-resistant, and visually...

€2.80 *

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Adam Hall Hardware 1632 KEEP BLK - Aufbauschließe für 17343 BLK, Stahl, schwarz galvanisiert

Adam Hall Hardware 1632 KEEP BLK - Keeper plate for 17343 BLK, steel, black galvanised

Keeper plate for 17343 BLK, steel, black galvanised Suitable for the Adam Hall 17343 BLK overlatch butterfly latch • Black galvanized steel – robust, corrosion-resistant, and visually...

€3.24 *

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Adam Hall Hardware 17251 S BLK - Butterfly-Verschluss groß, gefedert und gekröpft, in 13,9 mm

Adam Hall Hardware 17251 S BLK - Butterfly fastener, large, spring-loaded and cranked

Butterfly fastener, large, spring-loaded and cranked, in 13.9 mm deep recessed dish, black Large butterfly fastener in offset recessed dish • Dish depth: 13.9 mm • Outfitted with...

€19.90 *

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Adam Hall Hardware 17302 BLK - Overlatch Butterfly-Verschluss, groß, 14 mm tief, schwarz

Adam Hall Hardware 17302 BLK - Overlatch butterfly latch, large, 14 mm deep, black

Overlatch butterfly latch, large, 14 mm deep, black Overlatch butterfly latch • Large mounting tray, 14 mm depth • Black galvanized steel – robust, corrosion-resistant, and visually...

€18.90 *

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Adam Hall Hardware 17343 BLK - Overlatch Butterfly-Verschluss, klein, 9 mm tief, schwarz

Adam Hall Hardware 17343 BLK - Overlatch butterfly latch, small, 9 mm deep, black

Overlatch butterfly latch, small, 9 mm deep, black Overlatch butterfly latch • Small mounting tray, 9 mm depth • Black galvanized steel – robust and corrosion-resistant...

€16.90 *

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Adam Hall Hardware 17373 S BLK - Butterfly-Verschluss klein, gefedert, in kleiner Schale, 9,8 mm

Adam Hall Hardware 17373 S BLK - Small butterfly latch, spring-loaded, in small dish

Small butterfly latch, spring-loaded, in small dish, 9,8 mm deep, black Compact butterfly latch in miniature format • Recessed dish with a dish depth of 9,8 mm • Outfitted with integrated...

€11.90 *

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Adam Hall Hardware 26055 - Klavierband aus verzinktem Stahl, vorgebohrt, 635 mm

Adam Hall Hardware 26055 - Galvanised steel piano hinge, pre-drilled, 635 mm

Galvanised steel piano hinge, pre-drilled, 635 mm Galvanised steel piano hinge • Pre-drilled mounting holes (76 mm each) • 635 mm long / 38.8 mm wide • Fits between the lid stays of...

€11.42 *

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Adam Hall Hardware 372101 - Lenkrolle 100 mm, mit blauem Rad und A/B-Feststeller

Adam Hall Hardware 372101 - Swivel castor 100 mm, with blue wheel and A/B-brake

Swivel castor 100 mm, with blue wheel and A/B-brake Double ball race swivel for smooth and precise steering behaviour • Sturdy housing made of 2 mm steel for high load-bearing capacity...

€15.90 *

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