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 37501 S Eckaufbaurolle mit weichem Rad 75 mm

Adam Hall Hardware 37501 S - Surface Mount Corner Castor with soft Wheel 75 mm

Surface Mount Corner Castor with soft Wheel 75 mm with soft wheel with ball bearing • silent running • : Product type: Castors • Type: corner-mount castor • Wheel diameter: 75...

€16.80 *

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Adam Hall Hardware 4026 Ecke zweischenklig vernickelt mit Abkantung

Adam Hall Hardware 4026 - Case Corner two-leg nickel-plated with wrapover

Case Corner two-leg nickel-plated with wrapover Third leg bent inward for max. 20mm wood thickness. Third leg bent inward for max. 20mm wood thickness. : Product type: Corners • Type: Ball...

€0.75 *

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Adam Hall Hardware 4026 BLK Ecke zweischenklig schwarz mit Abkantung

Adam Hall Hardware 4026 BLK - Case Corner two-leg black with wrapover

Case Corner two-leg black with wrapover Third leg bent inward for max. 20mm wood thickness. Third leg bent inward for max. 20mm wood thickness. : Product type: Corners • Type: flat corner...

€1.15 *

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Adam Hall Hardware 873901 Auszugschiene für versenkbare Türen

Adam Hall Hardware 873901 - Drawer Slide for Sliding Doors

Drawer Slide for Sliding Doors Sliding-door drawer for building a sliding door system in cases. To be mounted on the sides, top or bottom. Best used with top edge capping 6145 and sprung sliding...

€36.63 *

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Adam Hall Hardware 1650 K Steckschlüssel für 1650

Adam Hall Hardware 1650 K - Square T-Key for 1650

Square T-Key for 1650 : Product type: Catch Accessories • Material: Steel • Surface: galvanized • Weight: 0,043 kg •

€8.84 *

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Adam Hall Hardware 3401 Griffschale Kunststoff schwarz

Adam Hall Hardware 3401 - Insert Handle plastic black

Insert Handle plastic black : Product type: Handles • Type: Insert Handles • Material: Plastic • Surface: nature • Color: Black • Material thickness: 2 mm • Handle...

€1.75 *

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Adam Hall Hardware 34083 Klappgriff mittel gefedert in Einbauschale 13 mm

Adam Hall Hardware 34083 - Recessed Sprung Handle medium in Dish 13 mm deep

Recessed Sprung Handle medium in Dish 13 mm deep In 9 mm deep dish with rivet protection • Zinc plated steel, 5.1 mm mounting holes • : Product type: Handles • Type: Folding Handles...

€5.46 *

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Adam Hall Hardware 3476031 Versenkter Ausziehgriff 2 Auszüge, schwarze Sch

Adam Hall Hardware 3476031 - Recessed Extendable Handle 2-stage, black cranked Dish length 336 -

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

€53.56 *

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Adam Hall Hardware 37041 Lenkeinbaurolle mit Schwerlastrad

Adam Hall Hardware 37041 - Swivel Castor with Heavy Duty Wheel

Swivel Castor with Heavy Duty Wheel The main features of this swivel castor are high stability, low height and excellent steering abilitie. This heavy duty ball bearing castor has a low noise level...

€12.58 *

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Adam Hall Hardware 37042 Lenkeinbaurolle mit Kunststoffrad

Adam Hall Hardware 37042 - Swivel Castor with plastic Wheel

Swivel Castor with plastic Wheel The ball bearing-free castor consists of impact-resistant PA (Polyamide). This castor is mounted on a 10 mm deep, galvanized steel fitting. The overall height after...

€9.17 *

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Adam Hall Hardware 40002 Kugelecke quadratisch mit Stapelmulde

Adam Hall Hardware 40002 - Ball Corner Square with Stacking Dimple

Ball Corner Square with Stacking Dimple Corner based on the corner 4000, but made of 1.2 mm steel and with ball. Like the corner 4000 this corner fits exactly to the lidmakers 6134 and 6146. In...

€1.04 *

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Adam Hall Hardware 40405 L-Ecke 50 x 80 gekröpft

Adam Hall Hardware 40405 - Corner Brace 50 x 80 cranked

Corner Brace 50 x 80 cranked This corner brace makes it possible to eliminate the small piece of case angle between corner brace and ball corner when building lids. Suitable for lid heights of 80...

€0.98 *

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Adam Hall Hardware 4044 - Corner Brace 40 x 50

Corner Brace 40 x 50 : Product type: Corner Braces • Material: Steel • Surface: galvanized • Color: silver • Material thickness: 1.2 mm • Mounting hole diameter: 5.1 mm...

€0.49 *

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Adam Hall Hardware 4071 EXT Kunststoff Kantenschutz

Adam Hall Hardware 4071 EXT - Plastic Case Angle

Plastic Case Angle : Product type Profiles • Type case angles • Material Plastic • Surface nature • Color Black • Length 2000 mm • Leg length 41 mm • Material...

€1.39 *

Content: 1 m

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Adam Hall Hardware 4107 Kugelecke groß dreischenklig gekröpft 30 mm 3-Loch

Adam Hall Hardware 4107 - Ball Corner large three-leg cranked 30 mm 3 holes

Ball Corner large three-leg cranked 30 mm 3 holes Ball Corner three-leg : Product type: Corners • Type: Ball corner • Material: Steel • Surface: galvanized • Color: silver...

€1.40 *

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Adam Hall Hardware 41261 Kugelecke mittel mit integrierter L-Ecke 42,5 mm

Adam Hall Hardware 41261 - Ball Corner Medium Cranked 30 mm with integrated Corner Brace 42,5 mm

Ball Corner Medium Cranked 30 mm with integrated Corner Brace 42,5 mm with Stacking Dimple : Product type: Corners • Type: Ball corner • Material: Steel • Surface: galvanized...

€1.24 *

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Adam Hall Hardware 4128 Kugelecke mittel dreischenklig gekröpft 30 mm mit

Adam Hall Hardware 4128 - Ball Corner Medium Three-Leg Cranked 30 mm with Stacking Dimple

Ball Corner Medium Three-Leg Cranked 30 mm with Stacking Dimple Ball Corner three-leg stackable : Product type: Corners • Type: Ball corner • Material: Steel • Surface: galvanized...

€1.19 *

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Adam Hall Hardware 4271 Stabilisierungskreuz 6,7 mm

Adam Hall Hardware 4271 - Cross for Dividing Walls 6.7 mm

Cross for Dividing Walls 6.7 mm : Product type: Flightcase Partitioning • Type: dividing wall hardware • Material: Steel • Surface: galvanized • Material thickness: 1.2 mm...

€1.48 *

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Adam Hall Hardware 4272 Trennwandbefestigung 6,7 mm

Adam Hall Hardware 4272 - Mount for Dividing Walls 6.7 mm

Mount for Dividing Walls 6.7 mm : Product type: Flightcase Partitioning • Type: dividing wall hardware • Material: Steel • Surface: galvanized • Material thickness: 1.2 mm...

€1.19 *

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Adam Hall Hardware 4292 Trennwandbefestigung 9,2 mm

Adam Hall Hardware 4292 - Mount for Dividing Walls 9.2 mm

Mount for Dividing Walls 9.2 mm : Product type: Flightcase Partitioning • Type: dividing wall hardware • Material: Steel • Surface: galvanized • Material thickness: 1.2 mm...

€1.27 *

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Bralo 55924025 Blindniete Standard 4,0 x 25,0 mm

Bralo 55924025 - Pop-Rivet Standard 4.0 x 25.0 mm

Pop-Rivet Standard 4.0 x 25.0 mm Single-sided application (blind rivet) • Covers a large clamping area • Blind rivets can be inserted from both sides. • Can be used to connect...

€0.05 *

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Bralo 55924821 Blindniete Standard 4,8 x 21,0 mm

Bralo 55924821 - Pop-Rivet Standard 4.8 x 21.0 mm

Pop-Rivet Standard 4.8 x 21.0 mm Single-sided application (blind rivet) • Covers a large clamping area • Blind rivets can be inserted from both sides. • Can be used to connect...

€0.07 *

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Palmer MI CAB CASTORS Rollensatz mit 4 Rollen inkl. Schrauben für Bass- un

Palmer CAB CASTORS - Castor Set with 4 Castors incl. Screws for Bass or Guitar Cabinets

Castor Set with 4 Castors incl. Screws for Bass or Guitar Cabinets Castor set with 4 castors (2 brakes) incl. screws for bass or guitar cabinets : Construction: swivel castor with brake...

€16.90 *

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Adam Hall Hardware SPLIT-LID 2er Set Butterfly Verschluss kurz gekröpft 14

Adam Hall Hardware SPLIT-LID - Bag of 2 Butterfly Latch short Cranked 14 mm deep with Split Dish

Bag of 2 Butterfly Latch short Cranked 14 mm deep with Split Dish The Split-Lid -Butterfly from Adam Hall makes building flight cases with split lids or hoods really easy. For one, the number of...

€46.42 *

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