How to Design a Road Case

EN vejsag (also known as an ATA or flight case) is a heavy-duty shipping container built to protect sensitive gear during transpor. It must safeguard equipment like musical instruments, audio and lighting production systems, stage props, and more when moved frequently by truck or plane. Flight/transit cases for fragile gear are custom-built with reinforced edges and corners, while road cases commonly carry band instruments, lighting rigs, or props on tour. Designing an effective road case means planning for maximum protection (against shock, vibration, moisture, etc.), an organized interior layout, robust materials, and rugged hardware. Below we cover the key principles B2B buyers and event professionals should follow – including design steps, use cases, and custom vs. standard case options.

Key Design Considerations

• Shock & Vibration: Use resilient, closed-cell foam or shock mounts to cushion equipment during drops or rough transit. For example, expanded polyethylene (EPE) foam is widely used for cushioning and impact absorption. Interior shock-absorbing foam inserts (cut to fit each item) or spring-isolated racks will dampen vibrations and prevent components from shifting.

• Moisture & Dust: Seal the lid with a rubber gasket and use moisture-resistant panel laminates. This helps keep out water and dust – important for outdoor events or humid environments.

• Modstandsdygtighed over for slag: Reinforce all case edges and corners. Install heavy-duty steel ball corners and riveted extruded frames so the case can withstand impacts. Stamped sheet-steel corner fittings (often nickel- or zinc-plated) protect the case during drops.

• Stacking & Load: Build to ATA-300 standards so the case can survive repeated use (typically 100+ round trips). Case faces should support heavy loads – ATA Category I tests require stacked weights (135 kg) on each face. Use high-quality laminated panels and hardware that won’t deform under a full stack.

• Accessibility & Handling: Include recessed, spring-loaded handles and sturdy casters for easy transport. Use piano hinges along one long edge, and consider gas struts or torsion rods to hold lids open. Make sure latches (butterfly or spring-draw types) are robust and lockable, and that the case can be carried or rolled without straining equipment.

Materialer og konstruktion

Most road cases use laminate panel construction: a tough outer skin bonded to plywood. Common configurations include:

• Laminate Panels: An outer layer of ABS plastic or fiberglass laminate is glued to a mid-layer of 3/16″–1/2″ cabinet-grade plywood (birch, poplar, maple, etc.). These two layers form a laminate panel. High-grade cases may use composite panels or aluminum for reduced weight.

• Aluminum Frame: Panels are joined by riveted aluminum extrusions along all edges. Any exposed plywood edge is capped with aluminum for splinter resistance.

• Corner Reinforcement: Each corner has a stamped steel ball corner. These heavy-duty corner fittings (often chromed, nickel-plated or zinc-plated) absorb shocks and allow safe stacking.

• Hardware Mounting: Rivets (steel or pop rivets) fix panels to the frame, typically spaced about 3″ apart. All fasteners should be industrial-grade to handle vibration.

By choosing the right panel thickness and materials, the case balances durability with weight. For example, thicker plywood and premium laminates increase strength (and cost), while thinner or composite panels may reduce weight for airline travel.

Internal Layout and Cushioning

Customizing the interior ensures gear is secure and organized:

• Tilpassede skumindsatser: Cut foam blocks or use CNC-cut foam trays to exactly fit each piece of udstyr. This foam absorbs shocks and keeps items from rattling. Closed-cell polyurethane or polyethylene foam is ideal.

• Rack Mounts: For audio/IT gear, install 19″ rack rails inside the case. Equipment can be bolted to racks, and rubber isolators or shock-absorbing mounts can further protect sensitive component.

• Compartments & Dividers: Create padded compartments or removable dividers for accessories (cables, microphones, tools). Keeping small items separated prevents them from jostling other gear.

• Cable Pass-Throughs: If equipment stays connected (like a rack amp), drill rubber-sealed holes for power or signal cables so the case can remain closed during setup.

• Venting: If the case will house powered equipment, add mesh vents or fans to prevent overheating. Ensure vents have filters or covers to keep dust out.

Planning the interior layout based on actual gear dimensions is critical. It’s often best to measure each item and draw a layout before cutting any materials.

Hardware and Accessories

Choose heavy-duty flight-case hardware certified for touring:

• Handles: Recessed steel handles (with rubber grips) allow comfortable lifting even when the case is tight against a wall. Spring-loaded handles retract when not in use. Ideally, fit handles on two opposite sides for balanced carrying.

• Latches and Locks: Use latch systems built into the case, such as butterfly (spring-loaded draw latches) or twist-latches. These should tightly clamp the lid to the case body. Many cases also have padlock hasps or cylinder locks on latches for security.

• Hinges: A piano hinge (continuous hinge) along the back edge is common. It spreads load and prevents twisting. For heavier lids, gas struts or torsion bars help keep the lid open safely.

• Wheels/Casters: Heavy-duty rubber or polyurethane casters make moving loaded cases easy. Choose swivel casters with brakes for maneuverability. For air shipping, many designs allow removal of wheels so they don’t protrude or get damaged.

• Labels and Identification: Attach an engraved placard or vinyl label area for serial numbers, asset tags, or company logos. Quick visual ID helps crews manage many cases on tour.

• Environmental Seals: For use in rain or dusty stages, add neoprene gaskets to lids and feature tight-close draws. This turns the case into a weather-resistant “flight case” suitable for outdoor events.

Typical Use Cases

Road cases are essential in live production and events. Common examples include:

• Lighting Equipment: Cases designed for moving-head fixtures, LED PARs, fresnel lights, etc. Interiors often have foam cavities or shelves sized for each lamp, plus space for DMX cables and safety chains.

• Audio Consoles & Mixers: Large mixing boards and consoles need shallow, padded cases with sliding racks or rails. Smaller mixers, amplifiers, and signal processors each fit into padded, rack-friendly sections.

• LED Screens & Video: Fragile LED panels (like video wall modules) travel in reinforced flight cases with internal rails or slings to hold each flat panel upright. Foam layers or padded crossbars protect the glass surface.

• Musikinstrumenter: Guitars, drums, keyboards, and percussion all have specialty cases with precisely cut foam or custom mounts to protect fragile parts. Drum cases, for example, often accommodate entire drum sets with drumhead and hoop protection.

• Broadcast/Camera Gear: Cameras, lenses, tripods, and lighting kits are organized in modular foam with cutouts for each piece. The sturdy exterior shields sensitive electronics.

• Trade Show/Display Cases: Booth lights, banner stands, and display racks (exhibition materials) pack into trunk-style cases with wheels, making setup and teardown smoother than using cartons.

By examining actual equipment needs, you can tailor case designs. For instance, touring band cases might include pull-out drawers for cables, while corporate AV flight cases might prioritize compact stackability.

Custom vs. Standard Solutions

Manufacturers typically offer both off-the-shelf models and bespoke designs to fit any need:

• Off-the-Shelf Cases: Standard case sizes (e.g. 12U or 24U 19″ rack cases, PA speakers, projector cases) are mass-produced and readily available. These models suit common equipment and quick-replacement scenarios.

• Fully Custom Cases: Custom units are built to order. You specify every detail – interior foam layout, exact dimensions, hardware options, color and logos. Custom cases can incorporate unique features like slide-out monitors, work-surfaces, or specialty foam.

• Bulk/Wholesale Orders: For large tours, rental companies, or retail distributors, custom road case wholesale solutions are ideal. Ordering cases in bulk can lock in pricing and ensure consistency. Many manufacturers (including sxpowercase.com) provide discounted rates and synchronized production for bulk orders.

• Branding & Appearance: You can often choose standard colors or add company logos/paint. Some cases even come with removable graphic panels for event graphics or sponsor branding.

Whether you need a few custom units or a fleet of identical cases, working with an experienced flight case manufacturer ensures you get exactly the features required. They will understand ATA-300 guidelines and can advise on which standardized components can save cost versus where full customization is necessary.

Working with a Manufacturer

Partnering with a specialized case builder streamlines the process:

• Design Consultation: Manufacturers can review equipment lists and suggest optimal layouts, materials, and case types. They often provide CAD drawings or 3D models for approval.

• Quality and Testing: Reputable builders fabricate cases to meet or exceed industry standards. Although ATA 300 compliance is self-certified, many manufacturers test cases (drop, vibration, water spray) internally to ensure reliability.

• Consistent Production: A flight case manufacturer has dedicated facilities for laminating panels, machining foam, and assembling cases. This consistency means your entire order will use the same parts and tolerances.

• Volume Capability: Large manufacturers can handle high-volume runs (dozens or hundreds of cases) efficiently, which is crucial for big concert tours or corporate rollouts.

• After-Sales Service: Many suppliers offer repair kits or case refurbishment, which is important for long-term rental fleets.

Procurement specialists should note that sourcing directly from a case manufacturer often yields better pricing and custom support than buying from third-party resellers. For B2B buyers, this means access to protective touring cases og event equipment road cases designed specifically for professional use, with warranties and service options.

Konklusion

Designing a durable, functional road case involves carefully balancing protection, layout, materials, and hardware. By following best practices – such as using rugged laminate panels, reinforcing all edges, and fitting equipment with shock-absorbing foam – you ensure that lighting, audio consoles, LED displays, or any event gear arrives safely on site.

As a flight case manufacturer, SX Power Case provides both custom and standardized solutions for businesses. For custom road case wholesale needs or specialized protective touring cases, visit our website or contact us for a quote. Our team will help tailor high-quality event equipment vejsager and bulk orders to suit your project requirements.