A flight case is a durable, rigid trunk or enclosure designed to protect goods during transit and storage, also known as an equipment or transit case.

Typically constructed from plastic or metal, many models include additional features such as heavy-duty foam inserts or extra protective padding for enhanced security.

Flight cases are widely used across various industries, including avionics, transport, electronics, entertainment, test and measurement, medical, security, and military sectors.

These cases are primarily engineered to safeguard fragile or high-value items during transport. Some are custom-designed to fit specific equipment or instruments, while others are versatile and can be used to protect a wide range of items from potential damage.

Complete Flight Case Guide

In this guide, we will explore the numerous options available when purchasing a flight case or equipment case.

 What is a Flight Case?

A flight case is a durable, rigid trunk or enclosure designed for protecting goods during transit and storage. Many models feature additional options like heavy-duty foam inserts or extra protective padding for enhanced security.

 Applications of Equipment Travel Cases

Equipment travel cases are widely used across various industries and applications, including avionics, transport, electronics, entertainment, test and measurement, medical, security, and military sectors. Some are custom-made for specific equipment or instruments, while others are adaptable for a wide range of items that may be at risk of damage.


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Transit Case Materials

Equipment cases are available in various materials, with the most common options explained below.

Aluminium Flight Cases

Among the most common types of metal transit cases used in airlines are aluminium flight cases, which are widely used in Aviation Industries. Available in both large and small sizes, they provide an ideal solution for safely transporting delicate or high-quality goods over long distances. Typical uses include shipping fragile electronics, instruments, and tools.

Lockable aluminum cases with foam padding are extremely durable, typically featuring reinforced or ribbed cast aluminum side and top panels for enhanced strength. They often include hinged lids, secure fastenings, ergonomic comfort grip handles, and sturdy, smooth-rolling caster wheels for easy transport.

Many aluminum flight case models are designed with reinforced, impact-resistant corners. This enhances protection during travel and allows for easier stacking, minimizing storage space.

Like most protective cases, metal versions often feature removable PE foam inserts lining the walls, base, and lid, providing superior protection against damage.

Plastic Flight Cases

Plastic flight cases are a popular choice due to the impressive blend of durability and lightweight design provided by modern polymers. Many of these cases are virtually indestructible under typical transport conditions, offering robust protection against impacts and knocks. Additionally, they provide a certain level of water and chemical resistance.

These cases are available in a wide range of configurations, with advanced IP ratings ensuring comprehensive protection against moisture, humidity, dust, and dirt. Many high-ingress protection models feature thick rubber seals and double-step latching systems, delivering exceptionally reliable performance when closed and secured.

Moreover, plastic flight cases often come with various other benefits and features, including:

Tough, scratch-resistant, double-walled construction

Strong wheels with steel bearings

Automatic pressure equalization valves

Retractable, easy-reach extension handles

Internal foam supports to keep important items safe and secure

Flight Cases with Foam

Padded equipment cases offer significant advantages, primarily due to the use of durable foam padding inserts. This padding greatly enhances the protection of contents, reducing the risk of damage from knocks, scrapes, and bumps during transit. As a result, equipment cases with foam are often chosen for delicate instruments and items that could be easily damaged if they come into contact with the hard surface of the case.

Flight cases with foam are available in various sizes to accommodate different types of contents. Additionally, wheeled versions are offered to facilitate easy maneuverability, making transportation more convenient.

Lightweight Flight Cases

When storing and transporting large or heavy items, it’s important that the case itself doesn’t add unnecessary bulk. Many of the best lightweight flight cases are made from sturdy plastic or cast aluminum, materials that offer an excellent balance of strength, rigidity, and durability while remaining easy to lift and move.

You may be pleasantly surprised by the maneuverability of some larger lightweight cases. These cases are often easily stackable when not in use, with some models featuring stacking locators embedded in their secure-latching lids, making storage even more convenient.

Waterproof Equipment Cases

Waterproof equipment cases not only protect against moisture but also offer robust defense against dust and dirt ingress. When choosing a case for a specific task or environment, it's essential to consider the IP rating, which indicates the level of protection you need.

These dustproof and waterproof cases can be made from materials like aluminum, with some models graded for protection against chemicals and environmental hazards such as humidity, rain, spills, and dust.

Regardless of the material, key features to look for include thick rubber seals or O-rings around openings, hinges, and latches. These components ensure a watertight (and sometimes completely airtight) interior, even under varying pressures at different altitudes.

Additionally, some models come equipped with automatic one-way pressure release valves, which help maintain balanced conditions inside the case, keeping the contents safe at all times.