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

SHOWGEAR Egg Foam 30 mm Set of 2 sheets of 1.5 m x 2 m

Set of 2 sheets of 1.5 m x 2 m : Length (mm): 1500 mm • Height (mm): 30 mm • Width (mm): 2000 mm • Fabric: Foam • Fabric Thickness: 30 mm • Colour: Gray •

€144.33 *

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

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

DAP Schaumdämmung Pearl, Dicke: 20mm Größe: 1m x 1.3m

SHOWGEAR Pearl Foam 20 mm Sheet of 1 m x 1.3 m

Sheet: 1 m x 1.3 m : Length (mm): 1000 mm • Height (mm): 20 mm • Width (mm): 1300 mm • Fabric: Foam • Fabric Thickness: 20 mm • Colour: Gray •

€31.45 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

SHOWGEAR 19 Inch Protection Panel with Locker 2U

19"/2U : Rack Units: 2 U • Colour: Black / Transparent • Height (mm): 88.9 mm • Width (mm): 482.6 mm • Flightcase Size: 19" • Material: Metal • Material...

€23.90 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Adam Hall Hardware 3476033 Versenkter Ausziehgriff 2 Auszüge, verzinkte Sc

Adam Hall Hardware 3476033 - Recessed Extendable Handle 2-stage, zinc-plated cranked Dish length

Recessed Extendable Handle 2-stage, zinc-plated cranked Dish length 336 - 661 mm Recessed extendable handle with two stages Locking mechanism with release button in the handle • to be mounted...

€52.81 *

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Delivery time: approx. 1 week

Adam Hall Hardware 8705 BLK Einbauschale schwarz ungestanzt

Adam Hall Hardware 8705 BLK - Dish black unpunched

Dish black unpunched Dish Opening Size: 115 x 67 mm • : Product type: Recessed Dishes • Dish material: Steel • Dish surface: Powder coated • Dish colour: Black • Dish...

€1.96 *

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Adam Hall Hardware 8705 Einbauschale verzinkt ungestanzt

Adam Hall Hardware 8705 - Dish Galvanized Unpunched

Dish Galvanized Unpunched Dish Opening Size: 115 x 67 mm • : Product type: Recessed Dishes • Dish material: Steel • Dish surface: galvanized • Dish colour: silver • Dish...

€1.52 *

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Delivery time: approx. 1 week

Adam Hall Hardware 019615 Plastazote (LD29) mit 7 mm Nuten 15 mm

Adam Hall Hardware 019615 - Plastazote (LD29) with 7 mm Grooves 15 mm

Plastazote (LD29) with 7 mm Grooves 15 mm PE foam "Plastazote" : Product type: Coverings and Foam Materials • Type: Foam Materials • Color: Black • Material: Plastazote...

€100.64 *

incl. tax, plus forwarding agency costs

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Bulky goods

OMNITRONIC T-Nut M5

Weight: 2 g •

Express delivery possible

€0.58 * €0.34 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Low stock; Delivery time: 1-3 days

Delivery time: 1-3 days

ACCESSORY Cross for Dividing Walls 6,7mm

Dimensions: Width: 0,60 cm Height: 0,60 cm • Weight: 0,03 kg •

€3.50 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

MONACOR RCP-8702U 482 mm (19") rack panel, 2 RS

482 mm (19") rack panel, 2 RS, closed. 1.5 mm steel, black plastic coating • Upper and lower edges angled (8 mm) in different configurations • Ideally suited for individual...

€11.00 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

Adam Hall Hardware 34731 Versenkter Ausziehgriff 2 Auszüge

Adam Hall Hardware 34731 - Recessed Extendable Handle 2-stage length 395 - 870 mm

Recessed Extendable Handle 2-stage length 395 - 870 mm Recessed extendable handle - three section: 39/22/25 cm : Product type: Handles • Type: Pull-out Handles • Extensions: 2...

€38.44 *

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Delivery time: approx. 1 week

Adam Hall Hardware 87600 Serviceklappe Höhe 25 cm

Adam Hall Hardware 87600 - Rack Door height 25 cm

Rack Door height 25 cm : Product type: Flightcase Accessories • Material: Steel • Surface: Powder coated • Color: Black • Width: 420 • Height: 250 mm • Cut-out size...

Express delivery possible

€60.62 *

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Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

Adam Hall Hardware 2270 L Aushängescharnier mit Stift verzinkt

Adam Hall Hardware 2270 L - Detachable Hinge with Pin Galvanized

Detachable Hinge with Pin Galvanized Lift-off slip hinges. Supplied in matching pairs with one long and one short pin enabling easy location of lid. Use on the left hand side when mounting...

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€2.61 *

incl. tax, plus shipping costs

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Delivery time: 1-3 days

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Adam Hall Hardware 2526 Feststellscharnier groß vernickelt

Adam Hall Hardware 2526 - Stop Hinge large nickel-plated

Stop Hinge large nickel-plated Large strut hinge : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface: nickel plated • Material thickness: 1 mm...

€1.59 *

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Delivery time: approx. 1 week

Adam Hall Hardware 2641 Kombination aus Scharnier und 2 L-Ecken

Adam Hall Hardware 2641 - L-shaped Hinge Steel Galvanized

L-shaped Hinge Steel Galvanized L-hinge large.Combination of corner brace 40403 and piano hinge 2606. : Product type: Hinges and Lidstays • Type: hinges • Material: Steel • Surface:...

€2.50 *

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Delivery time: approx. 1 week

Adam Hall Hardware 270755 Deckelfeststeller gekröpft mit Scharnier, Klick-

Adam Hall Hardware 270755 - Lid Stay cranked with Hinge Click-Stop Function and Rivet Protection

Lid Stay cranked with Hinge Click-Stop Function and Rivet Protection : Product type: Hinges and Lidstays • Type: lid stay • Dish material: Steel • Dish surface: galvanized...

€9.29 *

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Delivery time: approx. 1 week

Adam Hall Hardware 2810 Kofferinlett Netztasche

Adam Hall Hardware 2810 - Net Bag Case Insert

Net Bag Case Insert Net bag with zip Velcro (hooks) on backside • Similar to 2808 but 33 x 26 cm large so it´s big enough for A4 sized documents. • Perfect for manuals, remote...

€18.06 *

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Delivery time: approx. 1 week

EUROLITE KG-180S Kabelschloss zur Gerätesicherung mit Schlüssel

EUROLITE KG-180S Cable Lock Anti-theft Protection with Key

With this notebook lock, you can secure different devices such as notebooks, projectors, screens and battery-operated devices. The 1.80 m steel cable with plastic coating can easily be tied around...

€9.90 *

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Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

EUROLITE KG-180Z Kabelschloss zur Gerätesicherung mit Zahlenschloss

EUROLITE KG-180S Cable Lock Anti-theft Protection with Combination Lock

With this notebook lock you can secure different devices such as notebooks, projectors, screens and battery-operated devices. The 1.80 m steel cable with plastic coating and a 4-digit combination...

€12.90 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

ACCESSORY Isoliermatte, Noppen Höhe 50mm, 100x206cm

ACCESSORY Eggshape Insulation Mat,ht 50mm,100x206cm

Aucustic foam with 5 cm height Self-extinguishing according to MVSS302 • Made in Germany • Color: Anthracite • Dimensions: Length: 206 cm Width: 100 cm Height: 5 cm • Weight:...

€44.90 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

ROADINGER Stahlkugel-Ecke, 3 Schenkel 48mm

ROADINGER Steel Ball Corner, 3 legs 48mm

Ball corner, three-leg Steel ball corner • Diameter mounting holes: Ø4,5mm • Material: Steel, 1,2 mm • Color: Silver, zinc-plated • Dimensions: Width: 4,80 cm Depth: 4,80...

€1.30 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

ACCESSORY Steel Ball Corner, 64mm cranked

Ball corner Cranked for 30 mm edge protection and casemaker • Steel ball corner • Diameter mounting holes: Ø5,1mm • Material: Steel, 1,5 mm • Color: Silver, zinc-plated...

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€2.90 * €2.17 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days

ROADINGER Plastik-Ecke, Schenkel 50mm, stapelbar

ACCESSORY Plastic Corner, 50mm legs, stackable

Plastic corner, stackable Inside radius 10 mm • Recessed mounting holes • Plastic corner • Diameter mounting holes: Ø3,5mm • Material: Plastic • Color: Black...

€2.63 *

incl. tax, plus shipping costs

Availability:

Delivery time: 3-5 days

Delivery time: 3-5 days

ROADINGER Corner Brace high, holes

L-corner Diameter mounting holes: Ø5,1mm • Material: Steel, 1,2 mm • Color: Silver, chromium-plated • Dimensions: Length: 3,20 cm Width: 4 cm Height: 4 cm • Weight: 0,02...

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€0.79 * €0.59 *

incl. tax, plus shipping costs

Express delivery possible

Availability:

Delivery time: 1-3 days

Delivery time: 1-3 days