3D Flight Cases - ultimate flight case construction

3D Flight Case Construction

Right from the start, our aim has been to deliver flight case perfection, from the choice of rivet, to the type of rubber used for the handle grip.

For more than 35 years we have worked closely with our specialist component manufactures, specifying our exact technical requirements and meticulously road testing each element to deliver the toughest most durable packaging solutions. So closely did we work with our main supplier Sam Robinson took a year out to work full time, enlightening their understanding of what was required from our customers and for Sam to better understand the manufacturing possibilities to achieve our aims.

While at first glance our flight cases might appear similar to others, the combination of unique components and specialist construction process that make our flight cases exclusive to 3D Flight Cases alone.


When we first began there were only a handful of flight case companies in the world. They all followed the same construction method - gluing and pinning 1/2" plywood together and adding the protective edging afterwards.

Superior Flight Cases
3D Cases - Superior Construction - Stronger Flight Cases

The principle drawback of this method is that if a single glue joint breaks the whole flight case construction loses its integrity.

The reason for this problem with this single angle construction is that the strength lies in the rivet expanding and gripping within the soft plywood. While this might be fine for a case under little or no stress, once subject to continuous movement and impact, the rivet loses its grip within the soft plywood.

At this point the aluminium edging strip becomes nothing more than cosmetic cladding, providing little or no protection or strength to the case structure.


Flight Case Aluminium Extrusions
Quality Hardened Aluminium Extrusions

To overcome this problem, we designed a unique 'double angle' system using an extruded aircraft grade aluminium.

Our ‘double angle’ extrusion consists of an outside leg and an inner leg. This allows the case panels to be slotted into the channel, eliminating the problem of broken glue joints and making the aluminium edging an integral part of the case rather than an 'add-on'.

We also optimise the strength and rigidity of our cases by never inserting rivets into soft plywood.

Instead we rivet through the outside aluminium, via the case panel and 'pull up' the rivet on the inside aluminium leg so that it acts as a continuous reinforcing backing washer. This also effectively ‘crushes’ the aluminium onto the wood, trapping the flight case panel permanently within the extrusion.
Having made the 'double angle' section an integral part of our flight case construction, the joints will never work loose or break down over time.

The end result is a rigid, super-strength flight case with virtually no weight increase and the potential to last three decades or more.

Flight Case Construction
Not All Flight Cases Are Equal - Compare!
From our original extrusion we now offer aircraft quality hardened aluminium extrusions in 7mm for lighter applications, 10mm for general use and 13mm for heavy duty applications - each complemented with male and female closing location strips and dedicated corner braces for each size.

These allow us to incorporate a larger radius on the case edge, improving comfort when lifting and reducing any snagging.

Today all 3D Flight Cases are designed on screen and produced using precision CNC Martin MAChining.
This ensures all our case panels and spindles are millimetre perfect, creating an ultra-strong and seamless flight case system.


We believe we hold a duty to ensure the preservation of our global forest resources for the benefit of current and future generations. As such, 3D Flight Cases only offer the best in environmentally friendly, durable and long lasting transit protection for your equipment.

All our timber is sourced from responsibly managed forests using comprehensive, internationally recognised and independently audited Chain of Custody schemes.

In addition, after 30 years of expected use, you will be pleased to know that our flight cases are 95% recyclable.


Life for a professional flight case is hard. Nobody can predict how any one flight case is going to be treated or what it will endure during its life on the move, from continuous rough handling to extreme climates.

No one understands this better than 3D Flight Cases with our decades of experience and our customer feedback.

We constantly strive to improve our flight cases and invest a huge amount of time researching new designs and testing innovative materials to push the boundaries of our flight case performance.

Our sole aim is to provide you with the ultimate in flight case protection so that your sensitive and valuable equipment arrives in perfect working order day after day, year after year.

Not all flight cases are equal. 3D flight cases set standards leaving others trying to imitate

Why Trust Your Equipment To Any Other Flight Case?

Require further information?
Our friendly and experienced team are always on hand to welcome any questions about our flight cases or other products and services.
Please call 01733 269026 or drop us an email and say [Mouse over to reveal].

3D Flight Cases Facebook 3D Flight Cases Twitter
Subscribers know more!

This website is owned and operated by 3D Flight Cases Ltd.
3D Cases Ltd. 4 Maunsell Road, Offerfair Business Park, Castleham Industrial Estate, St Leonards, Hastings, East Sussex, TN38 9NN, GB
3D Flight Cases Ltd. Intergen House, 65-67 Western Road, Hove, East Sussex, BN3 2JQ, GB
TEL: 01733 269 026 | FAX: 01733 530 535
Company No. 7538601 | VAT No. GB 112 3647 47
Business hours are | Local UK Time is 12:08 (24hr)
© Copyright 2011-2021 3D Flight Cases Ltd. All rights reserved.

Our website is optimised for all modern browsers along with a screen resolution of 1920 x 1080.
If you experience any problems viewing our pages please email [Spam Bot Protected - Mouse over to reveal].


"A picture paints a
 thousand words."
 Frederick R. Barnard 1921