Flight Case
A flight case (or road case) is a protective container with reinforced corners, handles, and latches designed to safely transport LED panels and production equipment. Quality flight cases protect panels from impact, vibration, and environmental hazards during trucking and handling.
Understanding Flight Cases
Flight cases are engineered protective enclosures that make it possible to safely transport sensitive LED equipment between venues. Quality cases are essential for rental operations and touring productions.
Flight Case Construction
**Shell Materials:**
- Plywood (3/8" to 1/2" typical)
- ABS plastic (lightweight)
- Aluminum (premium)
- Composite materials
**Reinforcement:**
- Aluminum extrusion edges
- Steel or aluminum corners
- Ball corners for impact protection
- Riveted construction
**Hardware:**
- Recessed handles
- Heavy-duty latches
- Lid stays
- Stacking cups/feet
- Caster plates
Case Types for LED
**Panel Cases:**
- Hold 4-8 panels typically
- Foam dividers between panels
- Vertical orientation common
- Face-to-face panel protection
**Processor/Electronics Cases:**
- Shock-mounted rack rails
- Ventilation considerations
- Cable storage
- Front and rear access
**Accessories Cases:**
- Cable compartments
- Hardware organization
- Tool storage
- Document holders
Foam Insert Design
**Proper Protection:**
- Custom-cut for specific panels
- Firm foam (not soft packing foam)
- LED face protection
- Corner support
- Prevents shifting
**Common Foam Types:**
- Polyethylene (PE): Firm, durable
- Polyurethane (PU): Softer, shock-absorbing
- Crosslink: Premium protection
- Egg crate: Budget option
Handling Best Practices
**Loading:**
- Lift with handles only
- Don't exceed caster ratings
- Use ramps for truck loading
- Secure in truck properly
**Stacking:**
- Observe stack height limits
- Use stacking hardware
- Don't stack on soft surfaces
- Balance weight distribution
**Storage:**
- Climate-controlled preferred
- Away from direct sunlight
- Clean before storing
- Document contents
Case Maintenance
**Regular Inspection:**
- Check latches and hinges
- Inspect handles and corners
- Verify casters roll freely
- Examine foam for wear
**Repairs:**
- Replace worn foam
- Tighten loose hardware
- Fix damaged shells promptly
- Document repairs
Cost Considerations
Quality flight cases represent significant investment:
**Factors Affecting Cost:**
- Panel size and quantity
- Foam complexity
- Hardware quality
- Custom branding
- Caster type
**Cost-Benefit:** Cases that protect equipment save money through:
- Reduced damage claims
- Lower repair costs
- Equipment longevity
- Professional appearance
Labeling
Essential case labeling:
- Contents identification
- Quantity counts
- Weight (empty and loaded)
- Orientation arrows
- Company identification
- Contact information
Frequently Asked Questions
How many LED panels fit in a standard flight case?
Case capacity varies by panel size and case design. Common configurations hold 4-8 panels in a stacked arrangement with foam dividers. Always follow manufacturer specifications—overloading cases damages panels and creates handling hazards.
What should I look for in quality LED flight cases?
Essential features: reinforced aluminum corners, recessed latches and handles, foam inserts sized to panels, casters rated for loaded weight, stacking capability, and cable storage. Cases should fully protect panels from vibration and impact.
Should LED panels be shipped standing up or laying flat?
Follow manufacturer guidelines. Most panels ship face-to-face in vertical orientation to protect LEDs. Some lightweight panels may ship horizontally stacked. Never exceed stack height limits and always secure panels from shifting.
Related Terms
Apply This Knowledge
Use our LED video wall calculator to see how flight case affects your project specifications.
Try the Calculator