Case Design

By offering a full range of custom flight case designs in the UK, we ensure every customer receives a solution tailored not only to their equipment but also to their industry and workflow. Our bespoke flight cases are not one-size or type fits-all.

From lightweight briefcase style to heavy-duty road trunk flight cases and fully engineered rackmount flight cases, each type is designed with a specific purpose in mind. The differences between flight case designs depend on how your equipment is used, how frequently it is transported, and the level of protection, accessibility, and organisation required.

Choose a flight case design tailored to your equipment, transport needs, and working environment:

Rackmount Flight Cases Style

Rackmount flight cases are designed for equipment such as servers, amplifiers, control systems, and rack-mounted devices, built to fit within standard rack systems most commonly the 19-inch rack format used across audio, IT, and broadcast industries. The defining feature of this case type is the internal rack frame, which allows equipment to be securely mounted using standard unit measurements (U sizes) also referred to as rack units (RU).

While the 19” rack width is standard across the industry, the depth of equipment can vary significantly, which is where flexibility in design becomes essential. Different systems require different internal depths, clearances, and cable management space. This is where a bespoke approach makes a real difference, ensuring equipment fits correctly, operates efficiently, and remains fully protected during transport and use.

Some designs include fixed racks, while others incorporate shock-mounted systems to minimise vibration and impact particularly important for sensitive electronics. These cases typically offer access from both the front and rear, allowing for easy installation, maintenance, and operation without removing the equipment.

Rackmount flight cases are widely used in professional environments where equipment needs to remain securely installed, well-organised, and ready for immediate use, both in transit and on-site.

Tool Box Flight Cases Style

Toolbox-style flight cases are designed for organised storage, durability, and ease of access, making them a practical solution for transporting tools, equipment, and technical kits. Commonly used across industries such as engineering, events, maintenance, and backstage environments, this style allows for flexible internal layouts rather than fixed installations.

A key advantage of this style is the level of customisation available. Internal layouts can be tailored with drawers, divisions, foam lining, or open storage areas depending on the intended use. Drawer configurations are not fixed depth, height, and load capacity can all be adjusted, with heavy-duty runners capable of supporting substantial weight. Additional features such as front and rear access, cable flaps, and removable sections can also be incorporated where required.

Beyond internal layouts, the overall design can be adapted to improve functionality on-site. For example, lids can be engineered to double as work surfaces or tables with fold-out legs. Castors, handles, and structural elements are positioned based on how the case will be used in real working environments.

Manufactured in-house using high-quality birch plywood with a durable laminated finish, these cases are built for strength, longevity, and a clean professional appearance. With advanced manufacturing capabilities, the possibilities for configuration are extensive, allowing each case to be shaped around practical use rather than a standard format.

Briefcase Flight Cases Style

Slim-line and lightweight, briefcase-style flight cases are designed to offer both portability and protection for smaller, valuable equipment. Their format follows the principle of a traditional briefcase compact, easy to carry, and practical for everyday handling.

This style is most used for equipment that is not excessively heavy, typically suited to weights similar to standard luggage handling (max around 20–23kg). The focus is on ease of transport, allowing the case to be comfortably carried by hand while still providing reliable protection during transit.

Briefcase flight cases can be built to accommodate a wide range of items, including laptops, electronic components, prototype models, and specialist tools. Internally, they can feature anything from simple compartments to precision-cut foam inserts, depending on the level of protection and organisation required.

While designed primarily for portability, these cases can be adapted for heavier contents if needed. Additional handles, including side-mounted options, can be incorporated to improve handling. Handle types can also vary, from fixed carry handles to spring-loaded (recessed) handles, depending on preference and use.

Further practical features such as stacking corners can be added, allowing multiple cases to be safely stacked during storage or transport. Although sizes can vary in width and depth, the design typically prioritises ease of carrying and compact form.

Constructed with precision using advanced in-house machinery, briefcase flight cases can also include bespoke elements such as engraved logos or custom branding, combining protection with a clean and professional presentation.

Tray & Lid Flight Case

Tray and lid flight cases are designed to allow equipment to sit securely within a base (tray), while the lid provides protection during transport and can be easily removed when access is required. This structure makes it simple to lift equipment in and out without restriction, which is particularly useful for larger, heavier, or more delicate items.

The main purpose of this style is practicality during use. In many cases, the equipment is removed from the tray when in operation, meaning the case acts as both a transport solution and a safe housing when not in use. Because of this, features such as cable access points and service gaps are often incorporated, allowing equipment to be connected or tested without complete removal if required.

Internal foam or padding is carefully positioned to protect the equipment without interfering with its functionality. The lid is always fitted with foam in a way that holds the equipment securely in place during transit, preventing movement and ensuring consistent protection. This is especially important for items that need to remain operational or accessible, such as coffee machines used at events, air conditioning units, printers, mixing consoles or other technical equipment.

Tray and lid cases can be manufactured in a wide range of materials and finishes, depending on the level of durability and presentation required. Additional features such as reinforced bases, custom fittings, and tailored internal layouts can be incorporated to suit specific applications.

Overall, this style offers a balance between protection, accessibility, and ease of handling, making it a practical choice for equipment that needs to be frequently moved, accessed, or operated in different environments.

Workstation Flight Cases

Workstation flight cases are designed to combine transport, protection, and on-site functionality in one complete solution. Unlike other cases, this style transforms from a protective transport unit into a fully usable workstation within minutes, making it ideal for live events, production environments, and technical setups.

Internally, these cases often include sliding shelves, pull-out trays, and dedicated equipment bays, allowing gear to remain installed and ready for use. The design supports both accessibility and workflow, reducing setup time and keeping everything in one integrated system.

Due to their purpose, workstation cases are typically built to handle heavier equipment and more complex setups. Heavy-duty castors, reinforced structures, and strategically positioned handles ensure they can be moved safely while maintaining stability during operation.

Customisation plays a significant role in this style. Layouts can be adapted to include rack sections, storage compartments, cable management systems, and operator-friendly working heights. Every element is designed around how the workstation will be used in real conditions.

Workstation flight cases are widely used in industries such as audio production, live events, broadcasting, DJ setups, and technical control environments, where efficiency, protection, and quick deployment are essential.

Road Trunk Style

Road trunk flight cases are one of the most widely used and recognisable flight case styles, designed for general-purpose storage, protection, and transport of equipment. Their robust box construction and top-opening design make them a highly versatile solution across a wide range of industries.

Commonly used in broadcast, motorsport, live events, music production, and technical environments, road trunks are ideal for transporting multiple items within a single, organised case. Unlike more specialised case types, they are designed to offer flexible internal space, allowing equipment of different shapes and sizes to be stored safely together.

Internally, road trunks can be configured with fixed or removable divisions, as well as lift-out trays to create structured storage levels. Both the case interior and trays can be fully lined with foam or carpet, providing protection for delicate equipment such as monitors, cables, and accessories while also reducing movement during transit.

The deeper base section allows for storage of larger or heavier items, while upper tray levels help keep frequently used equipment organised and easily accessible. This layered layout improves efficiency during packing, transport, and on-site setup.

The lid can be either fully removable or hinged, depending on the intended use. A removable lid provides full access to the interior, while a hinged lid offers quicker operation in environments where frequent opening is required.

Additional features such as stacking corners, label dishes, recessed handles, and heavy-duty castors enhance usability, transport efficiency, and safe handling.

Designed to withstand frequent transport, heavy loads, and demanding working conditions, road trunk flight cases provide a reliable and adaptable solution for professionals who require durable, high-capacity equipment storage.

Aluminium Rigidised Cases

Our aluminium rigidised cases are designed for customers who need a reliable, lightweight solution with a clean, professional finish. Although they can be manufactured in formats like briefcase or trunk-style cases, this range is defined by its distinct aluminium construction and textured surface, which sets it apart from traditional flight cases but also helps reduce overall weight without compromising durability.

Aluminium rigidised cases are widely selected across different industries due to their practical, strength, durability and reduced weight:

Aluminium panels provide solid protection while keeping the case easier to carry and handle.
The rigidised pattern helps minimise visible marks from handling and improves overall durability.
Naturally resistant to corrosion. Suitable for long-term use in a variety of environments.
Commonly paired with foam inserts or internal divisions to keep contents secure and organised.

Aluminium rigidised cases are often chosen for technical and electronic equipment, medical and diagnostic devices, tools and specialist instruments, demonstration and presentation kits, equipment requiring organised, protective storage

Rather than being limited to a single case style, aluminium rigidised cases are selected for the properties of the material itself. This allows them to be adapted across multiple formats while maintaining a consistent look and level of protection.

Custom Flight Cases Manufacturer UK