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 37450S BLK - Einbau-Eckrolle mit weichem Rad, 75 mm, schwarz

Adam Hall Hardware 37450S BLK - Recessed corner castor with soft wheel, 75 mm, black

Recessed corner castor with soft wheel, 75 mm, black Soft 75 mm wheel made of polyurethane • Ball bearing • Die-cast aluminium housing • 5.1 mm mounting holes • 100 kg load...

€17.80 *

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Adam Hall Hardware 4000 BLK - Ecke quadratisch, klein, schwarz

Adam Hall Hardware 4000 BLK - Square case corner, small, black

Square case corner, small, black Small, square case corner made of galvanised steel, black. 37 mm in size, fixing holes with 5.2 mm diameter. : General Material: Steel • Coating: Galvanised...

€2.58 *

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Adam Hall Hardware 54M6X20F - Flachrundschrauben M6 x 20 mm, Stahl verzinkt, DIN 603

Adam Hall Hardware 54M6X20F - Cup head square neck screw M6 x 20 mm, steel galvanised, DIN 603

Cup head square neck screw M6 x 20 mm, steel galvanised, DIN 603 Cup head screws with square neck (DIN 603) • M6 x 20 mm • galvanised steel • Ideal for mounting enclosures, rack...

€0.11 *

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Adam Hall Hardware 54M6X25F - Flachrundschrauben M6 x 25 mm, Stahl verzinkt, DIN 603

Adam Hall Hardware 54M6X25F - Cup Head Square Neck Screw M6 x 25 mm, Steel galvanized, DIN 603

Cup Head Square Neck Screw M6 x 25 mm, Steel galvanized, DIN 603 Cup head screws with square neck (DIN 603) • M6 x 25 mm • galvanised steel • Ideal for mounting enclosures, rack...

€0.11 *

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Adam Hall Hardware 54M6X30F - Flachrundschrauben M6 x 30 mm, Stahl verzinkt, DIN 603

Adam Hall Hardware 54M6X30F - Cup head square neck screw M6 x 30 mm, steel galvanised, DIN 603

Cup head square neck screw M6 x 30 mm, steel galvanised, DIN 603 Cup head screws with square neck (DIN 603) • M6 x 30 mm • galvanised steel • Ideal for mounting enclosures, rack...

€0.12 *

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Adam Hall Hardware 54M6X35F - Flachrundschrauben M6 x 35 mm, Stahl verzinkt, DIN 603

Adam Hall Hardware 54M6X35F - Cup Head Square Neck Screw M6 x 35 mm, Steel galvanized, DIN 603

Cup Head Square Neck Screw M6 x 35 mm, Steel galvanized, DIN 603 Cup head screws with square neck (DIN 603) • M6 x 35 mm • galvanised steel • Ideal for mounting enclosures, rack...

€0.12 *

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Adam Hall Hardware 54M6X40F - Flachrundschrauben M6 x 40 mm, Stahl verzinkt, DIN 603

Adam Hall Hardware 54M6X40F - Cup Head Square Neck Screw M6 x 40 mm, Steel galvanized, DIN 603

Cup Head Square Neck Screw M6 x 40 mm, Steel galvanized, DIN 603 Cup head screws with square neck (DIN 603) • M6 x 40 mm • galvanised steel • Ideal for mounting enclosures, rack...

€0.13 *

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Adam Hall Hardware 54M6X45F - Flachrundschrauben M6 x 45 mm, Stahl verzinkt, DIN 603

Adam Hall Hardware 54M6X45F - Cup Head Square Neck Screw M6 x 45 mm, Steel galvanized, DIN 603

Cup Head Square Neck Screw M6 x 45 mm, Steel galvanized, DIN 603 Cup head screws with square neck (DIN 603) • M6 x 45 mm • galvanised steel • Ideal for mounting enclosures, rack...

€0.16 *

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Adam Hall Hardware 87973 - Kabeldurchlass in runder Einbauschale

Adam Hall Hardware 87973 - Cable gland in round dish

Cable gland in round dish Recessed round dish with star-shaped slotted rubber flange • For feeding through connectors and cables • Delivered uncut, must be cut open by the user • The...

€8.60 *

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Adam Hall Hardware 1907 Aufbauschloss klein vernickelt abschließbar

Adam Hall Hardware 1907 Drawbolt small nickel-plated lockable

Drawbolt small : Product type: Catches • Type: Drawbolt catches • Material: steel • Surface: nickel plated • Mounting hole diameter: 3.5 mm • Lockable: yes • Width: 34...

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€4.20 * €3.81 *

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Adam Hall Hardware 5312 Einschlagmutter M6

Adam Hall Hardware 5312 - Teenut M6

Teenut M6 : Product type: Fittings • Material: Steel • Color: silver • Thread size: M6 • Weight: 0,001 kg •

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€0.18 *

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Bralo 55914820 Blindniete Multigrip 4,8 x 19,5 mm

Bralo 55914820 - Pop-Rivet Multigrip 4.8 x 19.5 mm

Pop-Rivet Multigrip 4.8 x 19.5 mm "Multi-range properties (Multi Grip) can be used with a wide range of clamping areas. • "Single-sided application (blind rivet) • "Blind...

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€0.15 * €0.07 *

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Bralo 55924806 Blindniete Standard 4,8 x 6,0 mm

Bralo 55924806 - Pop-Rivet Standard 4.8 x 6.0 mm

Pop-Rivet Standard 4.8 x 6.0 mm Single-sided application (blind rivet) • Covers a large clamping area • Blind rivets can be inserted from both sides. • Can be used to connect...

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€0.05 *

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Adam Hall Hardware 2602 SHIM - Unterlage für Scharnierstück 2602, Stahl verzinkt

Adam Hall Hardware 2602 SHIM - Base for hinge piece 2602, galvanised steel

Base for hinge piece 2602, galvanised steel Matching base for hinge piece 2602 • Made from 1.5 mm thick galvanised steel • Used to compensate for the thickness of aluminium profiles 6126...

€4.18 *

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Adam Hall Hardware 270837 BLK - Deckelfeststeller groß, gekröpft, mit Scharnier

Adam Hall Hardware 270837 BLK - Large lid stay, cranked, with hinge and click-stop function, black

Large lid stay, cranked, with hinge and click-stop function, black Made of rugged steel, black galvanised • Cranked design • Dish depth: 10 mm • Integrated hinge and click-stop...

€21.90 *

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Adam Hall Hardware 340822 BLK - Klappgriff mit PVC-Griff, klein und gefedert

Adam Hall Hardware 340822 BLK - Folding handle with PVC grip, small and spring-loaded

Folding handle with PVC grip, small and spring-loaded, in 8 mm deep recessed dish, black Folding handle with PVC-coated grip • Spring-loaded design for secure fixing in resting position...

€14.90 *

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Adam Hall Hardware 4044 BLK - L-Ecke, 6-Loch, 40 x 50 mm, schwarz

Adam Hall Hardware 4044 BLK - L-corner, 6-hole, 40 × 50 mm, black

L-corner, 6-hole, 40 × 50 mm, black L-corner made of steel, 1.2 mm thick • Surface: black, galvanised • Height: 40 mm • Leg size: 50 mm • 6 fixing holes for stable...

€1.60 *

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Adam Hall Hardware 41046 BLK - Kugelecke groß, dreischenklig gekröpft, 35 mm, 6-Loch, schwarz

Adam Hall Hardware 41046 BLK - Large ball corner, three-legged cranked, 35 mm, 6-hole, black

Large ball corner, three-legged cranked, 35 mm, 6-hole, black Large, three-legged ball corner with six mounting holes • Material: steel, 1.5 mm thick • Surface: black galvanised...

€3.60 *

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Adam Hall Hardware 4124 BLK - Kugelecke mittelgroß, dreischenklig gekröpft, 30 mm, schwarz

Adam Hall Hardware 4124 BLK - Ball corner, medium, three-legged, cranked, 30 mm, black

Ball corner, medium, three-legged, cranked, 30 mm, black Medium three-legged ball corner with 3 mounting holes • Material: steel, 1.5 mm thick • Surface: black, galvanised • Cranked...

€2.80 *

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Adam Hall Hardware 8705G - Dichtungsring für mittlere Einbauschale

Adam Hall Hardware 8705G - Sealing ring for medium-sized recessed dishes

Sealing ring for medium-sized recessed dishes Sealing ring made of 1 mm thick foam rubber • Suitable for medium-sized recessed dishes: 8705, 8705BLK, 8708BLK, 87085BLK, and 87086BLK...

€0.60 *

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Adam Hall Hardware 87086 BLK - Stahl-Einbauschale für powerCON® TRUE1 Kombi-Buchse, schwarz

Adam Hall Hardware 87086 BLK - Steel recessed dish for powerCON® TRUE1 Combi Socket, black

Steel recessed dish for powerCON® TRUE1 Combi Socket, black Recessed dish for powerCON® TRUE1 Combi Socket (NAC3PXTRUE1) • Cut-out dimensions: 112 x 65 mm • Made from sturdy steel...

€4.02 *

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Adam Hall Hardware 8780 - Aktive Lüftungseinheit inkl. Netzteil und Temperatursensor

Adam Hall Hardware 8780 - Active ventilation unit incl. mains adapter and temperature sensor

Active ventilation unit incl. mains adapter and temperature sensor Active ventilation unit for ventilating racks and cases • Low-noise fan with switchable airflow direction (supply or...

€59.00 *

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Adam Hall Hardware 8781 - Große Lüftungsschale zur passiven Belüftung

Adam Hall Hardware 8781 - Large ventilation tray for passive ventilation

Large ventilation tray for passive ventilation Large ventilation tray for cases and racks • Large opening for high airflow rate • Suitable for active ventilation unit 8780 • The Adam...

€12.28 *

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SHOWGEAR Schwarze Vertiefung für selbstklebende Tour-Etiketten für selbstklebende Tour-Etiketten

SHOWGEAR Black Recessed Label Dish for Self-Adhesive Tour Labels for Self-Adhesive Tour Labels

Black • Steel • Recessed • Mount this black steel, recessed label dish to a flight case and attach the separately available self-adhesive tour label to easily identify the contents...

€4.85 *

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