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

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Adam Hall Hardware 4900 M 16 AH - Set 16 x GUMMIFUß 25 x 11 mm im Beutel

Adam Hall Hardware 4900 M 16 AH - Set 16 x RUBBER FOOT 25 x 11 mm in Bag

Set 16 x RUBBER FOOT 25 x 11 mm in Bag Rubber foot with steel insert : General Material: PVC-P (plasticized polyvinyl chloride) • Insert: Steel • Colour: Black • Stackable: No...

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Adam Hall Hardware 4903 M 24 AH - Set 24 x GUMMIFU ß 20 x 9 mm im Beutel

Adam Hall Hardware 4903 M 24 AH - Set 24 x RUBBER FOOT 20 x 9 mm in Bag

Set 24 x RUBBER FOOT 20 x 9 mm in Bag Rubber foot with steel insert : General Material: PVC-P (plasticized polyvinyl chloride) • Insert: Steel • Colour: Black • Stackable: No...

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Adam Hall Hardware 4903 M 40 AH - Set 40 x GUMMIFUß 20 x 9 mm im Beutel

Adam Hall Hardware 4903 M 40 AH - Set 40 x RUBBER FOOT 20 x 9 mm in Bag

Set 40 x RUBBER FOOT 20 x 9 mm in Bag Rubber foot with steel insert : General Material: PVC-P (plasticized polyvinyl chloride) • Insert: Steel • Colour: Black • Stackable: No...

€8.72 *

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Adam Hall Hardware 4904 M 16 AH - Set 16 x GUMMIFUß 25 x 15 mm im Beutel

Adam Hall Hardware 4904 M 16 AH - Set 16 x RUBBER FOOT 25 x 15 mm in Bag

Set 16 x RUBBER FOOT 25 x 15 mm in Bag Rubber foot with steel insert : General Material: PVC-P (plasticized polyvinyl chloride) • Insert: Steel • Colour: Black • Stackable: No...

€7.66 *

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Adam Hall Hardware 4906 M 24 AH - Set 24 x GUMMIFUß 38 mm x 10 mm im Beutel

Adam Hall Hardware 4906 M 24 AH - Set 24 x RUBBER FOOT 38 mm x 10 mm in a Bag

Set 24 x RUBBER FOOT 38 mm x 10 mm in a Bag Rubber foot with steel insert : General Material: PVC-P (plasticized polyvinyl chloride) • Insert: Steel • Colour: Black • Stackable: No...

€11.22 *

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DAP-Audio Flightcase Label SHOWTEC, magnetic with 3M tape + marker

Showtec Flight Case Magnetic Label With 3M tape and marker

Magnetic board material • Self-adhesive 3 m tape on backside • Including special marker pen • : Height (mm): 113 mm • Width (mm): 170 mm • Length (mm): 1 mm •

€2.81 *

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ACCESSORY Aluminium Case Angle 25x25mm per m

Aluminum case angle Delivered in 2-meter-pieces • Price per meter • 25 x 25 mm • Weight approx. 180 g/m • Made in Germany • Weight: 0,332 kg •

€2.76 *

Content: 1 m

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ACCESSORY Aluminium Case Angle 30x30mm per m

Aluminum case angle Delivered in 2-meter-pieces • Price per meter • 30 x 30 mm • Weight approx. 240 g/m • Made in Europe • Weight: 0,3 kg •

€4.50 *

Content: 1 m

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ACCESSORY Hybrid-Schließprofil 9mm pro m

ACCESSORY Aluminium Hybrid Lid 9mm per m

Aluminum hybrid lid location Delivered in 2-meter-pieces • Price per meter • For 9.5 mm panel • Weight approx. 220 g/m • Made in Europe • Weight: 0,3 kg • Feeding: For...

€9.32 *

Content: 1 m

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OMNITRONIC Modul 2HE 1x Kaltgerätedose 44x88mm

OMNITRONIC Module 2U 1x IEC female 44x88mm

2 U • Housing design: 2 U • Weight: 0,38 kg •

€0.75 *

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OMNITRONIC Adapterschraube 1,5cm auf 1cm 10x

OMNITRONIC Adapter Screw 1,5cm to 1cm

Thread reducer Reduced from 1.5 cm (5/8") to 1 cm (3/8") • Type (general stands): Accessory • Weight: 12 g •

€14.50 *

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ROADINGER Schaumstoffeinsatz 576x376x100mm

ROADINGER Foam Material for 576x376x100mm

Dimensions: Width: 57,6 cm Depth: 37,6 cm Height: 10 cm • Weight: 0,51 kg •

€29.90 *

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ACCESSORY Isoliermatte, Noppen Höhe 20mm, 50x100cm

ACCESSORY Eggshape Insulation Mat,ht 20mm,50x100cm

Aucustic foam with 2 cm height Self-extinguishing according to MVSS302 • Made in Germany • Color: Anthracite • Dimensions: Length: 100 cm Width: 50 cm Height: 2 cm • Weight:...

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ACCESSORY Isoliermatte, Noppen Höhe 70mm, 50x100cm

ACCESSORY Eggshape Insulation Mat,ht 70mm,50x100cm

Aucustic foam with 7 cm height Self-extinguishing according to MVSS302 • Made in Germany • Color: Anthracite • Dimensions: Length: 100 cm Width: 50 cm Height: 7 cm • Weight:...

€14.97 *

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ROADINGER Butterfly-Schloss Smartlatch für 10mm

ROADINGER Butterfly lock Smartlatch für 10mm

Inside-locking smartlatch for cases Locking inside the case • Quick to fit • Made in Europe • Weight: 370 g •

€16.50 *

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DAP Schaumdämmung Soft, Dicke: 20mm Größe: 1,5m x 2m

SHOWGEAR Soft Foam 20 mm Sheet of 1.5 m x 2 m

Sheet: 1.5 m x 2 m : Length (mm): 1500 mm • Height (mm): 20 mm • Width (mm): 2000 mm • Fabric: Foam • Fabric Thickness: 20 mm • Colour: Gray •

€71.23 *

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SHOWGEAR Blindcap for D Hole

Cover plate for D-type holes : Rack Units: 0 U • Colour: Black • Height (mm): 30 mm • Width (mm): 25 mm • Material: Plastic • Material Thickness: 1 mm •

€1.00 *

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SHOWGEAR M6 Plastic Protection Ring

Washer countersunk : Rack Units: 0 U • Colour: Black • Length (mm): 15 mm • Height (mm): 6 mm • Width (mm): 6 mm • Material: Plastic • Material Thickness: 2 mm •

€0.24 *

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DAP-Audio Top-Einsatz für Multiflex Case 80/120 - 37 cm, Premium Line

SHOWGEAR Top-insert for Multiflex Case 80/120 Premium Line - 37 cm

: Height (mm): 125 mm • Width (mm): 545 mm • Depth (mm): 370 mm • Inner Height: 116 mm • Inner Width: 527 mm • Inner Depth: 352 mm • Weight: 2.59 kg • Material:...

€64.99 *

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DAP-Audio Tiefteiler für Multiflex Case 80/120 - Premium Line

SHOWGEAR Low-divider for Multiflex Case 80/120 Premium Line

: Height (mm): 455 mm • Width (mm): 528 mm • Depth (mm): 9 mm • Weight: 1.56 kg • Material: Wood •

€21.50 *

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DAP-Audio HHochteiler für Multiflex Case 80/120 - Premium Line

SHOWGEAR High-divider for Multiflex Case 80/120 Premium Line

: Height (mm): 580 mm • Width (mm): 528 mm • Depth (mm): 9 mm • Weight: 1.8 kg • IP Rating: IP20 (indoor use only) • Material: Wood • Material Thickness: 9 mm...

€24.50 *

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