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What is the Best Flight Case Material?

The best flight case material is aluminum because it is durable and light. However, the flight case material also depends on the specific usage.

Moreover, flight cases can have mixed layers of plywood, steel, and high-quality plastic.

To learn more about flight case materials and their advantages, continue reading below.

What are flight cases made of?

Flight cases can be made of aluminum, wood, and plastic, each depending on how the cases are used.

These flight case materials are used to cater to specific needs and purposes, such as transportation of light and heavyweight equipment.

For your reference, here’s a simple breakdown of different flight case materials:

Aluminum Flight CaseLightweight, durable, corrosion-resistantMore expensive, prone to denting and scratching
Plastic Flight CaseLightweight, affordable, corrosion-resistantLess durable, may crack or break under heavy impact
Plywood Flight CaseStrong, sturdy, versatileHeavier than aluminum, susceptible to water damage
<Pro & Con of different flight case materials>

Applications of Flight Cases Made of Different Materials

Aluminum Flight Case

  • Ideal for protecting delicate equipment such as audiovisual gear, cameras, and instruments during air travel or road transport; 
  • Commonly used in industries such as music, film, broadcasting, and the military for its lightweight yet robust properties

Plastic Flight Case

  • Best suited for lightweight applications where cost and weight are primary considerations, such as carrying cases for small electronics, tools, or promotional materials;
  • Frequently used in trade show exhibits, retail displays, and consumer electronics packaging for its affordability and ease of molding into various shapes

Plywood Flight Case

  • Suitable for heavy-duty applications where durability and customization are priorities, such as touring cases for musical instruments and production equipment;
  • Often used in the construction of flight cases for speakers, amplifiers, and lighting fixtures due to its strength and shock absorption qualities.
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Flight Cases FAQs

  • 1. How strong are flight cases?

    Flight cases are designed to be strong to accommodate heavy and bulky equipment. Flight cases can carry medical equipment, military supplies, sound boxes, and more.

  • 2. Why are flight cases so expensive?

    Flight cases are expensive because of the materials used. That being said, aluminum flight cases are priced higher than plywood and plastic ones.

  • 3. What can I use instead of a flight case?

    You can use soft cases, rack cases, hard cases, or cardboard boxes as an alternative to flight cases. However, they might not be able to withstand heavy and bulky equipment.

  • 4. What is the best wood for a flight case?

    The best wood for flight cases is birch plywood. It is known for its durability, strength, resistance to moisture, and warping.
    Other plywood types like maple or oak are also used for flight cases. However, they are not as durable and strong as birchwood.


Flight case materials vary depending on the purpose or usage. In most cases, flight cases are made of aluminum, wood, or plastic.

However, each flight case material has its own set of pros and cons.

For heavy-duty uses, it is recommended to use aluminum flight cases – but can be slightly expensive.

If your equipment is lighter, you can go for plywood or plastic material, which are often cheaper than aluminum.

Article Sources
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