Custom lightweight flight cases?

June 2, 2024 9:48 AM

I need a few cases to be frequently checked on airplanes and sometimes shipped via FedEx. These are for calibration boards that are pretty sturdy but need to be protected from impact and bending. The boards are 27"x20"x2". Up until now, we have been using metal-covered plywood cases, foam lined, which are 30"x22"x5" and have a handle on top...and very heavy. I'm hoping we can find a lighter solution. Any suggestions for where to go?
posted by SampleSize to Travel & Transportation (5 answers total)

I was thinking Pelican, but they don't make one in your size. I saw a company that makes custom cases that is even more robust than yours, with castors at the bottom, but they didn't bother listing the weight, which I imagine, would not be light at all. But that's for TVs. They have one for signs, which sounds like it's more suited for your purpose, but again, does not list the weight.
posted by kschang at 10:07 AM on June 2

You can make basically a more robust version of a cardboard box with coroplast (the stuff rigid plastic signs are made out of, basically the same as corrugated cardboard, which comes in various thicknesses, even in a double-walled version if you want). With a little foam inside and judicious selection of coroplast thickness, I think these would be plenty strong for your use case unless these boards are very susceptible to bending. Sheathing tape from the hardware store on the outside can help protect the corners of the box and keep everything tight and strong.

You can make these yourself or get them custom made, though I'm sure that would be expensive for small quantities.
posted by ssg at 10:19 AM on June 2 [2 favorites]

Check out Gator cases for audio gear. This one isn't quite big enough but weighs only 11lbs. (How heavy are your boxes that are too heavy?) If you poke around their products you can probably find something that will work.

Also please tell us what that board is used to calibrate!
posted by SaltySalticid at 10:20 AM on June 2 [1 favorite]

cases-and-enclosures.co.uk make very lightweight and affordable flight cases.
None of their standard cases are large enough, but they may be able to make a custom build for you, the minimum order for a custom size is 40 units. They ship to most countries.
posted by Lanark at 12:28 PM on June 2

Carbon fibre is the obvious solution for lightness/rigidity/impact protection. Any composites company could easily make cases from carbon lined with foam that would meet your needs. Cost may be an issue, of course.
posted by dg at 6:35 PM on June 4