Trifibre Guide to FAQs on Flight Cases
As the UK’s leading manufacturer of flight cases, Trifibre designs, builds and dispatches custom cases from our Leicester factory to customers nationwide. Since 1981, we’ve worked with the biggest names to provide bespoke flight cases for Fender, McLaren, Johnson & Johnson, Samsung and Airbus.
Read our comprehensive guide for more information on our manufacturing process or get a quote for custom flight cases.
- What are flight cases?
- What are flight cases made from?
- Are flight cases waterproof?
- How are flight cases made?
- Where can I buy flight cases?
What are flight cases?
Flight cases are reinforced and reusable shipping crates that are designed to safely store and transport high value, heavy or fragile goods. The sturdy design of a flight case can incorporate a range of features, including wheels for easy movement, latches and locking for easy loading and security, or interior foam for customised support.
Music and theatre industry professionals rely on flight cases to successfully transport musical instruments, sound and recording equipment, and lighting. While the medical, military, aerospace and defence sectors all use flight cases to store sensitive equipment, ensuring no damage is sustained during transit. The practical design and manoeuvrability of flight cases means they can also be used as mobile point of sale stands for shows, conferences and other events
The design of a flight case, from the size and shape to its specific features, vary depending on the need but the manufacturing process is key to making a flight case that correctly supports the equipment it is transporting to ensure safe delivery to its destination.
At Trifibre, all flight cases are designed using the latest CAD technology and routed using precision CNC routing to ensure precision throughout the manufacturing process.
What are flight cases made from?
Flight cases are mainly constructed from panels of plywood that are reinforced with steel corners and aluminium extrusions to make them highly durable. At Trifibre, the majority of our flight cases are made from phenol coated birch plywood, known as hexaboard, although we can also manufacture cases from a variety of panel materials including astraboard, plywood with laminate and diabond.
Hexaboard benefits from a rigid and hard wearing finish. It is more resilient, can accommodate greater weights and withstand impact, making it ideal for transporting goods. In addition to its strength, hexaboard protects from moisture while also being a cost-effective material and eco-friendly.
The exterior of our flightcases are manufactured using only the best fixtures and fittings, and additional features are carefully designed for maximum usability. Steel corners are combined with aluminium extrusions to protect the flight case from bumps and knocks during transit.
Recessed steel carry handles are a key feature that ensures the handles remain durable throughout the life of the flight case while helping to streamline storage. Internal high density foam padding should be added to a flight case to provide customised support and prevent the movement of equipment within the flight case.
For a more lightweight finish, a number of our flight case panels are constructed using astraboard. This offers a plastic alternative to traditional wooden flightcases and benefits from a polypropylene sandwich construction that is significantly lighter than hexaboard, making it an ideal solution where weight and manoeuvrability are key considerations.
Are flight cases waterproof?
Traditionally designed and manufactured flight cases are not fully waterproof as they are made using plywood, which may swell or warp if submerged. The riveted construction also allows for slight water ingress around the aluminium extrusions. At Trifibre, as standard we use a birch plywood hexaboard construction to make our flight cases moisture resistant. We can, on request, apply an internal seal around the extrusions and corners to further improve a flight case’s water resistance.
However, we stock a range of fully waterproof cases from a wide range of brands, including MAX and SKB, most of which are IP67 rated, drop tested and resistant to corrosion. Our waterproof hard cases are the most reliable designs available and can be supplied with foam interiors.
How are flight cases made?
Trifibre’s bespoke flight cases are all designed and made in-house in the heart of the East Midlands. We are specialists in flight case production and have invested heavily in the right people and the right equipment to manufacture the highest quality flight cases on the market.
Our flight case design is carried out using Solidworks 3D CAD. Our flight case production process starts with CNC precision routing via a Biesse CNC routing machine, which cuts the panels for each case with precision and maximum efficiency. We also utilise CNC routing for cutting custom foam inserts to ensure a precise, high quality finish.
An Addison CNC double mitre saw is used to cut aluminium extrusions, again with a focus on accuracy and efficiency.
The product process can be completed with UV printing or screen printing to provide digitally printed logos or graphics and branding to the exterior of the flight case.
Read about Trifibre’s in-house machinery to learn more about our flight case production processes.
Where can I buy flight cases?
You can buy a range of flight cases with foam inserts, wheels, drawers and more from Trifibre, search by size, industry or product type to find your ideal case. We manufacture bespoke flight cases and can provide one-off designs, wholesale orders and everything in between. With over 40 years’ experience in manufacturing and supplying flight cases, you can trust us to deliver a high quality product every time.