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

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:...

€19.90 *

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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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SHOWGEAR 19 Inch Protection Panel with Locker 4U

19"/4U : Rack Units: 4 U • Colour: Black / Transparent • Height (mm): 177.8 mm • Width (mm): 482.6 mm • Flightcase Size: 19" • Material: Metal • Material...

€31.90 *

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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 19 Inch Connector Panel 1U - for 8 XLR Connectors (D-Size)

Black : Rack Units: 1 U • Colour: Black • Height (mm): 44.45 mm • Width (mm): 482.6 mm • Flightcase Size: 19" • Material: Aluminium • Material Thickness: 2 mm •

€5.55 *

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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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AKG RMU40 Pro Pro Rack Mount Unit

Rack Mount Unit for SR45 (Perception Wireless), SR420, SR450, SR470.

€31.90 *

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Not in stock
Delivery time: approx. 2 weeks

Delivery time: approx. 2 weeks

AKG RMU40 MiniRack mount kit

Rack mount unit for WMS40 Mini and WMS40 Mini2.

€46.15 *

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Not in stock
Delivery time: approx. 2 weeks

Delivery time: approx. 2 weeks

MONACOR HF-10 Rubber feet

Rubber feet For small devices • Square • Self-adhesive • 13 x 13 x 3.5 mm • Sales unit: 44 pcs. • : Description: rubber foot • Type: self-adhesive • Colour: black...

€13.00 *

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MONACOR HF-155 Rubber foot

Rubber foot For heavy devices and speaker cabinets • With grooved profile • Hole: 5.2 mm • Ø 38 mm x 15 mm • : Description: rubber foot • Type: hole: 5.2 mm...

€1.00 *

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MONACOR CP-1/SW PA terminal

Terminals For building PA speaker systems and for general use, flush mounting, assembled or as recessed connector plates with pre-drilled holes, robust steel version, black lacquered. PA terminal...

€3.00 *

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Details

MONACOR CP-6/SW PA terminal

Terminals For building PA speaker systems and for general use, flush mounting, assembled or as recessed connector plates with pre-drilled holes, robust steel version, black lacquered. PA terminal 1...

€5.00 *

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MONACOR MZF-4012 Recessed head wood screws

Recessed head wood screws, (bag of 100). 3.5 x 12 mm • Flat half-round head • Black • Self-cutting • Supplied in bags of 100s: 1 x screw set MZF-....= 100 screws : Description:...

€7.72 *

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MONACOR CC-140V/SW Selbstklebendens Velours-Vlies, 1 m2

MONACOR CC-140V/SW Self-adhesive velour fleece

Self-adhesive velour fleece Black cover fabric • 1,400 x 750 mm, 1 m2 • Temperature-resistant up to 110 °C • Suitable e.g. for car boots, camper vans, coaches and caravans...

€15.46 *

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MONACOR MZF-1012 Carrying handle

Carrying handle To be screwed on • Zinc-plated steel version • Robust spring-loaded drop handle with rubber grip • Dimensions: 140 x 40 x 15 mm • : Description: carrying handle...

€6.00 *

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Adam Hall 19" Parts 87221 19" U-Rackblende 1 HE, Aluminium

Adam Hall 19" Parts 87221 - 19" U-Shaped Rack Panel 1 U Aluminium

19" U-Shaped Rack Panel 1 U Aluminium : Product type: 19" Rack Panels • Material: Aluminium • Surface: Powder coated • Color: Black • Height: 1 U • Width: 19...

€8.44 *

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Adam Hall 19" Parts 87224 STL 19" U-Rackblende 4 HE, Stahl

Adam Hall 19" Parts 87224 STL - 19" U-Shaped Rack Panel 4 U Steel

19" U-Shaped Rack Panel 4 U Steel : Product type: 19" Rack Panels • Material: Steel • Surface: Powder coated • Color: Black • Height: 4 U • Width: 19 "...

€9.51 *

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Adam Hall Hardware 1650 - Square Hole Turnlock

Square Hole Turnlock : Product type: Catches • Type: Turning Locks • Material: Steel • Surface: galvanized • Mounting hole diameter: 4.5 mm • Lockable: no • Width: 20...

€8.51 *

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Adam Hall Hardware 17202 2 HE Butterfly Verschluss

Adam Hall Hardware 17202 - 2 U Butterfly Latch

2 U Butterfly Latch : Product type: Catches • Type: Butterfly Latches • Material: Steel • Surface: galvanized • Mounting hole diameter: 4.2 mm • Lockable: no • Dish...

€7.75 *

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Adam Hall Hardware 17250 LS Butterfly Verschluss groß gefedert abschließba

Adam Hall Hardware 17250 LS - Butterfly Latch large with Spring lockable non cranked 14 mm deep

Butterfly Latch large with Spring lockable non cranked 14 mm deep Large butterfly spring catch with a shallow cylinder lock in the wing, mounted in a 14 mm deep dish. Provides tidy security and a...

€20.05 *

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Adam Hall Hardware 17250 SP Butterfly Verschluss groß gefedert ungekröpft

Adam Hall Hardware 17250 SP - Butterfly Latch Large with Spring non Cranked 14 mm Deep Padlockable

Butterfly Latch Large with Spring non Cranked 14 mm Deep Padlockable Butterfly large, with eyelet for a padlock. The closing mechanism of the butterfly is equipped with a counter pressure spring to...

€12.32 *

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Adam Hall Hardware 17284 Butterfly Verschluss mittel gekröpft 12 mm tief

Adam Hall Hardware 17284 - Butterfly Latch medium cranked 12 mm deep

Butterfly Latch medium cranked 12 mm deep Our V3, V4 and V5 Butterflies have a patented ´push-down` mechanism that lifts the hook out of the keeper plate on opening and leads it back into the...

€7.19 *

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Adam Hall Hardware 2801 Aktenkofferinlett

Adam Hall Hardware 2801 - Briefcase Insert

Briefcase Insert : Product type: Flightcase Accessories • Color: Black • Material: PVC • Material thickness: 15 mm • Width: 436 mm • Length: 290 mm • Weight: 0,35 kg...

€17.45 *

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