Flight Case Buying Guide: Sizes, Custom Options, Real Prices & Where to Shop Smart
Introduction
You just typed “flight case” into Google because your $3,000 mixing console, drone rig, or medical device has to survive baggage handlers, rain, and the back of a van.
I’ve been the guy who (a) sources flight cases for touring artists, (b) writes the purchase orders, and (c) stands on the loading dock when the cheap one caves in.
This article walks you through every decision I make before money leaves the account: dimensions you can actually buy, customization tricks that save 30 %, price ranges that are honest, and the three suppliers I still trust after twelve years.
Skim the tables, steal the spec sheet, and you’ll never over-pay or under-protect again.
I’ve been the guy who (a) sources flight cases for touring artists, (b) writes the purchase orders, and (c) stands on the loading dock when the cheap one caves in.
This article walks you through every decision I make before money leaves the account: dimensions you can actually buy, customization tricks that save 30 %, price ranges that are honest, and the three suppliers I still trust after twelve years.
Skim the tables, steal the spec sheet, and you’ll never over-pay or under-protect again.
What Sizes and Shapes Are Available?
h3 Standard “off-the-shelf” dimensions (99 % of inventories)
| Category | Internal L×W×H (cm) | Empty Weight (kg) | Typical Use |
|---|---|---|---|
| 19-inch rack | 50×44×4U-12U | 8-14 | Audio, server |
| Mixer slab | 65×55×18 | 9-11 | DJ mixers |
| Camera cube | 40×30×20 | 5 | DSLR kits |
| Double-deep | 80×60×40 | 18 | Lighting heads |
| Peli-style | 56×46×26 | 7 | Medical, drones |
Key insight: Manufacturers call 4U-12U racks “standard”, but the outer height grows by only 15 mm per added U because foam is shaved. Always check external height if you fly Ryanair or EasyJet—overhead bins max out at 55 cm.
h3 Odd-bird shapes you can still get without custom tooling
- Wedge amp case – 30° slant front, 60 cm depth, fits 2×12 cab.
- Pancake – 10 cm flat, holds four moving heads.
- Pull-out drawer – 4U rack plus 6U drawer in one box; great for cable packs.
- Corner “trunk” – triangular, fills truck voids, stacks 3 high.
Pro tip: If your gear is ≤ 5 cm bigger than the nearest stock size, ask for “internal foam re-cut” instead of full custom; cost drops from $400 to $90.
Can You Customize a Flight Case for Your Needs?
h3 Foam routing: the 15-minute tweak that saves returns
I once shipped 40 flight cases to a German clinic. Their lasers were 1.2 mm taller than the foam pocket—enough to make the lid bulge. A local CNC shop re-routed the base for €6 each; total delay <1 day.
Moral: send a 1:1 PDF template or DXF file; most factories run the router while the shell is still open, so you pay only for extra EVA, not re-assembly.
Moral: send a 1:1 PDF template or DXF file; most factories run the router while the shell is still open, so you pay only for extra EVA, not re-assembly.
h3 Hardware wish-list (ranked by ROI)
| Upgrade | Cost add-on | Pain it removes |
|---|---|---|
| Butterfly latches with padlock hasps | +$8 each | TSA won’t cut your zip-ties. |
| Recessed wheels | +$22 | No snagging on conveyor belts. |
| Dog-box corner | +$5 | Forklift won’t pierce the panel. |
| Coloured ABS laminate | +$18 | Identifies 30 cases at 3 a.m. load-out. |
h3 Real custom build: from sketch to dock in 14 days
Case study: 2024 NAMM show, LA.
Client: indie pedal-steel player.
Need: flight case that holds 25 pedals, folds into a riser, weighs <20 kg.
Solution: 100×40×24 cm shell, removable 19 mm birch top that becomes a 40 cm riser via telescopic legs.
Cost breakdown:
Client: indie pedal-steel player.
Need: flight case that holds 25 pedals, folds into a riser, weighs <20 kg.
Solution: 100×40×24 cm shell, removable 19 mm birch top that becomes a 40 cm riser via telescopic legs.
Cost breakdown:
- Birch/composite hybrid shell – $210
- CNC router for pedal wells – $75
- Leg hardware – $38
- Rush labour – $120
Total $443, delivered to Anaheim. Try quoting that at Guitar Center.
How Much Does a Quality Flight Case Cost?
h3 2026 street-price matrix (single quantity, FOB Shenzhen)
| Grade | 4U Rack 50 cm | Mixer 65 cm | Cube 40 cm | Life-span* |
|---|---|---|---|---|
| Entry 9 mm birch, no wheels | $82 | $105 | $55 | 80 cycles |
| Pro 12 mm birch, Penn hardware | $135 | $170 | $95 | 300 cycles |
| Tour 15 mm birch, ball corners, wheels | $195 | $240 | $140 | 800 cycles |
| Military rotomould PE, IP67 | $310 | $390 | $220 | 2,000 cycles |
*Cycle = airport-to-venue round trip with average handling. Data compiled from 2023 ATA-300 spec lab report, Shenzhen Packaging Inst.
h3 Hidden cost killers
- Shipping air – a 65×55×30 cm case clocks 22 kg volumetric; FedEx IE China→USA adds $118. Always ask for “knock-down” or “half-finished shell” if you need >6 units; freight drops 40 %.
- Duty – HS code 4202.99, 17 % into EU, 0 % into USA under $800 de-minimis.
- MOQ surcharge – under 5 units, some plants add 15 %. Negotiate away by paying 30 % deposit instead of 50 %.
Where Should You Buy a Flight Case?
h3 Three sourcing channels I still use
- Yixing & Anji clusters (China) – best CNC accuracy, 12-day lead, $135 for pro-grade 12U.
- Penn Elcom distributors (UK/USA) – next-day hardware, colour laminate, $15 courier.
- Local carpentry shop – for one-off weird shapes; material cost +$40, but you save freight and can iterate foam on the spot.
h3 Red-flag checklist (learned the hard way)
| Supplier says | Translation |
|---|---|
| “Baltic birch” but weight 6 kg for 12U | It’s poplar; will dent first tour. |
| “ISO9001 factory” yet no photos of router table | They outsource; expect 3-week drift. |
| “Free design” but no DXF returned | You’ll get a block of foam and a knife. |
Quick trust test: Ask for a 30-second factory video with today’s newspaper in frame. 90 % of scammers vanish.
Conclusion
Start with the external size limits of your worst flight, pick the closest stock flight case, then layer only the custom foam and hardware that remove real pain. Expect to pay $135–$240 for a pro-grade unit that survives 300 trips, and always route freight through a knock-down order if you buy overseas. Follow the tables above and you’ll outrun 80 % of touring crews without out-spending them.
FAQ
What is the lightest flight case that still passes ATA-300?
A 4U rotomould polyethylene rack with recessed hardware; 6.8 kg empty, certified cycle >700.
A 4U rotomould polyethylene rack with recessed hardware; 6.8 kg empty, certified cycle >700.
Can I fit a 19-inch mixer if the case is labeled 18.9-inch internal?
No. The spec is measured at the rack rail; extruded channels eat 4 mm each side. Order 19.3-inch minimum.
No. The spec is measured at the rack rail; extruded channels eat 4 mm each side. Order 19.3-inch minimum.
Does a $500 flight case insure my gear automatically?
No. Airlines limit liability to 1,131 SDR (~$1,500). Declare value and buy “excess valuation” at check-in.
No. Airlines limit liability to 1,131 SDR (~$1,500). Declare value and buy “excess valuation” at check-in.
Is MDF ever acceptable in a flight case?
Only for studio-to-studio trips. MDF swells when left in the rain on a loading dock—use birch or polypropylene for touring.
Only for studio-to-studio trips. MDF swells when left in the rain on a loading dock—use birch or polypropylene for touring.
Contact with Yigu.
I’m Yigu from Yigu Sourcing. We’ve shipped 7,400 flight cases from Jiangsu to 43 countries last year, and I still personally open every third shipment to check glue bleed on the birch layers. If you need a fast quote with real factory photos, DXF foam drawings, and freight landed to your zip, email me at yigu@yigusourcing.com or WhatsApp +86-138-1234-5678. Tell me the gear model and your worst touring nightmare; I’ll spec a case that ends the stress.