Road Cases USA
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Custom road cases: frequently asked questions

Quick answers about ordering custom road cases, ATA flight cases and 19" rack cases from Road Cases USA.

How do I design a custom road case online?

Use our free 3D Case Designer above. Pick a case style (Shallow Lid, Hinged Lid, Front Lid, 19" Rack, 50/50 Split, or Shallow Base), enter your dimensions or, on desktop, load a Quick Start preset, and configure plywood thickness, exterior finish, color, interior lining, wheels and corner hardware. The 3D preview updates in real time so you can see exactly what you are ordering. The tool itself does not quote: every design leaves it marked "To Be Priced" and a real estimator prices it. When you're happy, click Send My Design. Our team responds within one business day.

Are Road Cases USA cases ATA-rated?

Yes. Our standard build (3/8" or 1/2" plywood with aluminum extrusion, ball corners, and recessed butterfly latches) meets ATA Category I specifications for repeated commercial air transport. We've supplied ATA-rated cases to touring artists, broadcast networks, theatrical productions and aerospace contractors since 1978.

What's the price range for a custom road case?

Every custom road case is quoted by a person, not by the tool. Designs leave the 3D Designer marked "To Be Priced" and our team returns a real figure within one business day. Cost is driven mainly by panel surface area, plywood thickness (1/4", 3/8" or 1/2"), exterior finish, how much hardware is on the case, how much foam and partition work the interior needs, quantity, and freight to your destination. See how pricing works for what moves the number.

How long does it take to get a custom road case quote?

One business day for the quote. After you click Send My Design, our team reviews your spec and responds within one business day with a real figure. The 3D Designer does not price your build itself: it marks every design "To Be Priced" and hands your dimensions, options and a rendered image straight to an estimator. Manufacturing lead time is confirmed on that quote, because it depends on the build and on current shop load.

What sizes can I order? Is there a minimum or maximum?

Any size from 4" to 96" per dimension. We've built everything from a 6" pedalboard case to 8-foot freight crates. There's no minimum order: single-unit custom builds are our standard. For bulk orders (50+ items overall, any mix of cases) we offer volume discounts; contact us with quantity for pricing.

Where are your custom road cases made?

Every custom road case ordered through the 3D Designer is built by hand in our New York facility from American Baltic-birch plywood, aluminum extrusion and chrome-plated steel hardware. Custom builds: Made in USA since 1978.

What kind of cases can I build with the 3D Designer?

Any size, any purpose. Common configurations include: 19" rack cases for pro audio and broadcast gear, custom rack cases for amplifiers and effects, TV and monitor flight cases, DJ controller and turntable cases, drum hardware cases, lighting fixture road cases, camera and video cases, trade-show crates, sports equipment cases, medical and aerospace transport cases, and military-spec shipping cases.

Can I add partitions and interior foam?

Yes. The 3D Designer supports up to 12 interior partitions per shell (left↔right, front↔back, or horizontal shelves) and a range of interior linings: carpet, bare plywood, and multiple thicknesses of soft and dense foam for cushioned protection. All options are reflected in your quote.

Do you ship internationally?

Yes. We ship worldwide. International shipping requires a separate quote since rates vary significantly by destination, case size, and freight method. For U.S. orders, we include shipping pricing directly in your quote. For international orders, request your design quote and our team will follow up with a freight quote for your destination.

What's the difference between a road case, a flight case, and an ATA case?

The terms are largely interchangeable. Road case is the U.S. industry standard term, popular in pro audio and touring. Flight case is the European-leaning term emphasising air-transport safety. ATA case refers specifically to a case meeting Air Transport Association Spec 300 / Category I: repeatedly survives commercial air freight without damage to contents. Every case we build meets ATA spec on the standard build (3/8" or 1/2" plywood with full hardware).

How long does it take to build a custom road case?

Manufacturing lead time is confirmed in writing on your quote, which comes back within one business day of sending your design. Lead time depends on the build itself (a single carpet-lined Shallow Lid case and a ten-case package with cut foam and partitions are very different jobs) and on current shop load, so we quote it per order rather than publishing one number. If you have a hard in-hand date, put it in the notes field when you send the design and we will tell you straight away whether it is achievable.

Is there a minimum order quantity for custom road cases?

No. There is no minimum order: single-unit custom builds are our standard work, and always have been. If you need one case, we will build one case. For fifty or more items overall, in any mix of cases, we offer volume pricing; send the design with the quantity in the notes, or start from bulk orders.

How do custom road cases ship, and how much is freight?

Small and accessory cases ship by parcel carrier. Anything large, heavy or on casters ships by LTL freight, usually strapped to a pallet. Freight is quoted with the case rather than added later, because the cost depends on the finished dimensions, the weight and the destination: a 12U rack to a loading dock and the same rack to a residential address are priced very differently. If the delivery point has no loading dock or needs a liftgate, put that in the notes field with your design and we will quote it correctly the first time. See shipping, warranty and returns.

Can you cut foam to fit my equipment exactly?

Yes. That is what the dense hard foam options are for. Dense foam holds a clean cut edge over time where soft foam eventually slumps, so it is the right base when you want each item sitting in its own pocket. A common pattern is a 1" or 2" dense foam base with soft foam above it as the crush layer. Pick a dense foam lining in the designer and describe the layout you want in the notes field, and we will spec the cut with your quote. More on choosing an interior lining.

Which plywood thickness do I need: 1/4", 3/8" or 1/2"?

1/4" (Light Duty) is for local gigging and storage: cases that ride in your own van and never go on a pallet. 3/8" (Standard Duty) is the default and the right pick for most orders: it handles commercial air freight, LTL trucking and rental-house turnaround, and it is the thickness behind our ATA Category I build. 1/2" (Heavy Duty) is for dense or heavy contents, long unsupported spans, stacked truck packs, and anything roughly over 48" on a side. Choose thickness from the weight of the contents, not the size of the case. See the plywood comparison table.

What are the actual outside dimensions of a 19-inch rack case?

The "19 inch" describes the width of the equipment's mounting panel, not the case. Once you add rack rails, plywood walls and aluminum extrusion, a finished 19" rack road case measures about 22.5" across the outside, which is why the designer fixes that width for you. Height is a multiple of 1.75" (one rack unit, or 1U), so 4U is 7" of panel, 8U is 14", 12U is 21". Add roughly two to three inches of interior height over the raw rail height for rails, hardware and cable clearance. Depth is up to you and should include room behind the deepest chassis for connectors and cable bend radius. Full chart: 19-inch rack basics.

Can I reorder the same case later, or send my design to a colleague?

Yes. Every design has a Share Design Link button that encodes the whole build into a URL. Send it to a colleague and it opens on their screen exactly as you left it. You can also save up to five designs in your own browser, and download a PNG render or a PDF spec sheet to attach to a purchase order. For a repeat build, send us the link or the previous quote number and we will match it.

Buyer's guide

Custom road cases: how to spec one that actually fits

Last updated .

Everything the 3D designer above asks you for, explained in the order it asks for it: what an ATA road case is, which plywood thickness to pick, how the six case styles differ, how 19-inch rack sizing works, and which interior lining protects what. Written from the same option catalog the configurator runs on, so nothing here is offered that you cannot actually build.

What the designer builds
Custom road cases, ATA flight cases, 19" rack cases and custom shipping cases. Designed in 3D, then hand-built to the spec you send.
Size range
4" to 96" on every side, in any combination. Dimensions are shown Width × Depth × Height.
Case styles
Six: Shallow Base, Shallow Lid, Hinged Lid, Front Lid, 19" Rack and 50/50 Split, plus Other for custom geometry.
Plywood
1/4" Light Duty, 3/8" Standard Duty, 1/2" Heavy Duty.
ATA rating
The standard build (3/8" or 1/2" plywood with aluminum extrusion, ball corners and recessed butterfly latches) meets ATA Specification 300 Category I.
Interior lining
Bare wood, carpet, soft foam at 1/2", 3/4", 1", 1 1/2" and 2", and dense hard foam at 1/2", 1" and 2".
Partitions
Up to 12 per shell: left-right dividers, front-back dividers, or horizontal shelves on the rack and front-lid styles.
19" rack width
Fixed at 22.5" outside. Height in 1.75" rack units; depth to your spec.
Minimum order
None. Single-unit custom builds are standard work; ten identical cases price better per unit, and fifty or more items overall qualify for volume pricing.
Price
The designer does not price anything. Every design leaves it marked "To Be Priced" and an estimator quotes it.
Quote turnaround
One business day after you send the design. Manufacturing lead time is confirmed on that quote.
Built in
Commack, New York. Custom builds: made in the USA since 1978.

What is an ATA road case?

Definition: An ATA road case is a reusable hard transport container built from laminated plywood panels captured in an extruded aluminum edge frame, closed with recessed butterfly latches, protected at every corner by a ball or flat corner cap, and built to the Air Transport Association's Specification 300 so it survives repeated commercial air and truck freight without the contents taking the load.

The three words buyers use interchangeably are not quite identical. Road case is the American touring and pro-audio term. Flight case is the more common term in Europe and emphasizes the air-transport side. ATA case is the only one of the three that points at a written standard: ATA Specification 300, published by the Air Transport Association, which classifies reusable shipping containers by how many trips they are engineered to survive.

What separates a real ATA case from a plywood box with handles is the assembly, not the label. The panel edges are trapped in aluminum extrusion rather than screwed to a frame, so impact energy travels around the perimeter instead of into the joint. The latches and handles sit in recessed dishes so nothing snags in a truck pack or breaks off under a stack. The corners take the drop, because a case that falls off a tail lift lands on a corner roughly every time.

The ATA Specification 300 categories

Our standard build (3/8" or 1/2" plywood with aluminum extrusion, ball corners and recessed butterfly latches) meets ATA Category I for repeated commercial air transport. If your case has to satisfy a specific customer, carrier or contract spec, say so in the notes field when you send the design and we will confirm the build against it in writing.

Road case vs flight case vs ATA case: what is the difference?

Short answer: all three describe the same kind of container and are used interchangeably. Road case is the American touring and pro-audio word for it. Flight case is the European-leaning word and emphasizes the air-transport side. ATA case is the only one of the three tied to a written standard (ATA Specification 300, published by the Air Transport Association), so it is a statement about how the case is built, not about where it travels.

Road case vs flight case vs ATA case
TermWhere the term is usedWhat it meansTied to a standard?
Road case United States: touring, pro audio, rental houses A reusable hard transport case: plywood panels captured in an aluminum edge frame, closed with recessed latches and protected by corner caps. No, an industry term, not a specification.
Flight case Europe and much of the rest of the world The same case described from the air-freight side, emphasizing survival through baggage and cargo handling. No, also an industry term.
ATA case Anywhere a client, carrier or contract specifies it A case built to Air Transport Association Specification 300, which classifies reusable containers by how many round trips they are engineered to survive. Yes, ATA Spec 300, Categories I, II and III.

Because the three words overlap, the question worth asking a supplier is not which term they use but which ATA category the build actually meets. Our standard build meets ATA Category I, and every style in the designer can be built to it.

1/4", 3/8" or 1/2" plywood: which thickness should you choose?

Plywood thickness is the single decision with the biggest effect on both how much abuse the case absorbs and how much it costs you to ship for the rest of its life. Thicker plywood does not just add protection; it adds weight, and weight is what freight carriers bill on. The right answer is the thinnest panel that still survives your actual handling.

Plywood options in the 3D designer
OptionPanelBuilt forChoose it when
Light Duty 1/4" plywood Local gigging and storage The case rides in your own van, gets handled by people who care, and never goes on a pallet. Accessory cases, cable cases, small utility trunks. Lightest and least expensive to ship.
Standard Duty 3/8" plywood Flying and shipping (most common) The default, and the right pick for most orders. Handles commercial air freight, LTL trucking and rental-house turnaround. This is the thickness behind the ATA Category I claim.
Heavy Duty 1/2" plywood Maximum protection Heavy or dense contents, long unsupported spans, cases that get stacked in a truck pack, or anything where a replacement costs more than the freight. Also the sensible pick past roughly 48" on a side.

Two rules of thumb that catch most people out. First, thickness should follow the weight of the contents, not the size of the case: a 24" case holding a 90 lb motor wants 1/2", while a 60" case holding a foam-packed banner does not. Second, if cases will be stacked in a truck, the case at the bottom of the stack is the one that decides the spec, so add stacking wheel plates and step up a thickness.

The six road case styles, explained

Style is really a question about how you get your gear in and out, and the 3D designer renders each one so you can open it before you commit. All six take any dimension, any lining and any hardware combination.

Style A

Shallow Base

A thin base with a deep removable lid, roughly 30% of the depth in the base. Lift the lid straight off and the contents are sitting on a low tray, exposed on all sides.

Good for: work you do around the item. Camera and lens kits, microphone kits, tabletop displays, anything you unpack on a table.

Shallow base case quote form

Style B

Shallow Lid (most common)

The inverse and the industry default: a deep base holding roughly 78% of the depth, with a thin removable lid on top. The gear stays down in the case and protected while the lid is off.

Good for: nearly everything. Mixers, DJ coffins, stage pianos, guitars, amps, drum hardware, lighting and stand kits, trade-show crates.

Shallow lid case quote form

Style C

Hinged Lid

Same proportions as Shallow Lid, but the lid stays attached on a continuous piano hinge and swings open instead of lifting off.

Good for: a lid you do not want to lose, cases opened and closed many times a day, and any workflow where there is nowhere to set a loose lid down.

Style D

Front Lid

The lid covers the front face rather than the top, so the case opens toward you while it stays upright on its wheels.

Good for: gear that is operated in the case, front-loading equipment, and anything you cannot lift out. Accepts shelf partitions.

Front lid case quote form

Style E

19" Rack

A standard 19-inch rack with removable front and rear lids and a fixed 22.5" outside width. You choose the height in rack units and the depth; the width is set by the standard.

Good for: amplifiers, processors, wireless racks, playback and broadcast gear, network and control racks.

Rack case quote form

Style F

50 / 50 Split

Two equal halves, each a working compartment. Split it open and you have two usable trays instead of a lid and a base.

Good for: flat-screen displays and monitors, artwork and signage, anything thin and wide that you want supported from both faces.

Split case quote form

If none of the six is right, pick Other in the designer, build the closest shape and describe what you actually need in the notes. Custom geometry, drawers, doors, hinged front lids and combination cases are all standard work for us. The six styles are the fast path, not the limit. We also take quote requests by form for a briefcase, a front and back lid case, a pull-along case and a road trunk.

19-inch rack cases: the basics

Definition: A rack unit, written 1U, is 1.75 inches of vertical panel height in a 19-inch equipment rack. The "19 inch" refers to the width of the equipment's mounting panel, not the width of the case. Once you add rack rails, plywood walls and aluminum extrusion, a finished 19" rack road case measures about 22.5" across the outside.

That is why the 19" Rack style in the designer fixes the outside width at 22.5" and lets you choose only the height and the depth. Height is a multiple of 1.75", and depth is whatever your deepest chassis needs plus room behind it for connectors, cable bend radius and airflow. Rack depth is where most first-time buyers get it wrong: an amplifier that measures 17" deep needs meaningfully more than 17" of case, because the cable plugged into the back needs somewhere to go.

Rack units to panel height
Rack unitsPanel heightTypically holds
2U3.5"A single power amp or a pair of 1U processors
4U7"Effects rack, small wireless rack, utility rack
6U10.5"Playback rack, small control rack
8U14"Mixer rack, mid-size amp rack
10U17.5"Broadcast or AV integration rack
12U21"Touring rack, the workhorse size
14U24.5"Large amp or distro rack
16U28"Full production rack, usually with casters

The panel height column is the raw rail space your gear occupies. When you type a height into the designer, add roughly two to three inches on top of that number so the rails, rack hardware and cable service loop have somewhere to live. That is exactly what our Quick Start rack presets do. A 12U touring rack preset, for example, comes in at 24" of interior height against 21" of rail.

Carpet, foam or bare plywood: choosing the interior

The lining is what actually protects the contents; the case only protects the lining. There are ten interior options in the designer, in three groups.

Bare wood and carpet

Bare wood is the correct choice inside a 19" rack case, where the gear is bolted to rails and lining would only get in the way. Carpet is the classic road-case interior: it stops surface scuffs, it is quiet, it takes abuse for years, and it is what you want for hardware that is already rugged. Drum hardware, stands, cable, trunks and utility cases.

Soft foam: 1/2", 3/4", 1", 1 1/2", 2"

Soft foam compresses under impact and gives energy somewhere to go. Use it when the contents are fragile but not heavy. Thin soft foam (1/2" to 3/4") is light cushioning for panels, screens and flat items. 1" is the general-purpose protection thickness and the one most of our presets use. 1 1/2" and 2" are for genuinely delicate loads or long shipping legs. Note that foam eats interior space on every face, so add its thickness twice to each dimension when you are sizing the case.

Dense hard foam: 1/2", 1", 2"

Dense hard foam holds its shape under load instead of collapsing. That makes it the right base for heavy items, and it is the foam you want if the plan is to cut pockets so each item sits in its own cavity; soft foam will not hold a clean cut edge over time. 2" dense foam under a heavy chassis with soft foam above it is a common and very effective combination.

Partitions

Enable partitions and you can add up to 12 internal dividers per shell: left-to-right walls, front-to-back walls, or horizontal shelves on the rack and front-lid styles. Partitions are the cheapest way to turn one case into organized storage for many items, and the 3D preview has an x-ray and an open-case view so you can check the layout before you send it.

Exterior finish, color and hardware

Diamond Plate is a patterned black laminate imprinted with the classic diamond-tread look. It hides scuffs better than anything else we offer and it is always black, so the color picker locks when you select it. Laminate is the solid-color wrap and takes any of the six stocked colors: black, blue, red, white, yellow and grey. Color is not only cosmetic on a touring or trade-show job: color-coding cases by department is the fastest load-in tool there is.

For wheels you have three choices. Casters put four wheels on the bottom of the case, which is what you want for anything you push. Dolly wheels put two wheels on one end so the case tips back and pulls behind you like luggage. Better for narrow corridors and stairs, and for cases that stand upright in storage. No wheels keeps the case light and low, which is right for accessory cases, cases that live inside other cases, and anything that ships on a pallet.

Corner caps come as Ball (the standard rounded corner that takes the drop), Flat (a low-profile angled plate for a cleaner look and a tighter truck pack), or Stacking Ball (a ball with a center recess so cases nest into each other instead of sliding when stacked). The remaining hardware toggles are side handles, recessed hardware, padlockable latches for anything that needs to be sealed or security-tagged in transit, and stacking wheel plates so the case above locks onto the casters of the case below.

What the 3D designer supports: full specification

This is the complete option set the configurator will build. Anything outside it is still possible; it just needs a conversation rather than a click.

Road Cases USA 3D designer: supported specification
SpecificationWhat you can choose
Dimension range4" to 96" on every side, in any combination
Dimension referenceInterior usable space, outside of your item, or outside of the finished case
Case stylesShallow Base (A), Shallow Lid (B), Hinged Lid (C), Front Lid (D), 19" Rack (E), 50/50 Split (F), plus Other for custom geometry
19" rack widthFixed at 22.5" outside; height in 1.75" rack units, depth to your spec
Plywood1/4" Light Duty, 3/8" Standard Duty, 1/2" Heavy Duty
Exterior finishDiamond Plate (patterned black) or Laminate (solid color)
ColorsBlack, blue, red, white, yellow, grey (Laminate only; Diamond Plate is always black)
Interior liningBare wood, carpet, soft foam at 1/2", 3/4", 1", 1 1/2" and 2", dense hard foam at 1/2", 1" and 2"
PartitionsUp to 12 per shell: left-right dividers, front-back dividers, or horizontal shelves on rack and front-lid styles
WheelsFour casters on the base, two dolly wheels on one end, or none
CornersBall, Flat, or Stacking Ball
Hardware optionsSide handles, recessed hardware, padlockable latches, stacking wheel plates
Preview toolsFree-orbit 3D, auto-rotate, open-case view, x-ray partition view, measurement overlay, feature pins, person silhouette from 5'0" to 7'0" for scale, side-by-side A/B comparison
Take it with youPNG image, PDF spec sheet, shareable design link, and a multi-case quote cart for whole packages
QuoteMarked "To Be Priced" in the tool. A real quote comes back from our team within one business day
Build locationHand-built in Commack, New York. Custom builds: made in the USA since 1978

Who orders custom road cases, and what they order

Road cases for touring and live sound

The original market and still the hardest one. Consoles, amp and processor racks, wireless racks, backline, drum hardware, cable trunks and stage-piano cases that fly a hundred times a year. Standard Duty 3/8" with casters, carpet or foam, padlockable latches.

Related: mixer cases, speaker cabinet cases, music cases.

Road cases for AV integration and staging

Projectors, displays, switchers, processors and control racks that ship to a venue, work for three days and ship home. 50/50 Split for screens, 19" Rack for the head end, foam-lined trays for everything with a lens.

Related: projector cases, flat-screen and monitor cases, audio and video cases.

Road cases for broadcast and video production

Camera bodies, lens sets, matte boxes, monitors, comms and the rack that runs it all. Dense hard foam cut to pocket the kit, ball corners, padlockable latches, and a spec sheet that matches for every duplicate case on the truck.

Related: rack cases, microphone cases, computer and laptop cases.

Road cases for military, emergency response and industrial use

Deployable kit that has to arrive working: test equipment, tooling, spares, comms and response gear. Heavy Duty 1/2" plywood, stacking wheel plates, padlockable latches, dense foam, and interiors partitioned so an inventory check takes seconds.

Related: emergency response cases, lifting cases, trunk and utility cases.

Road cases for medical, laboratory and aerospace

Instruments where the shipping damage costs more than the case ever will. Dense hard foam bases with soft foam above, tight partitioning, Heavy Duty panels, and dimensions taken from the outside of the item rather than guessed.

Related: accessory and instrument cases, drawer cases and work boxes.

Road cases for trade show and experiential

Booth structures, tabletop displays, signage, product samples and the work box that becomes a counter on site. Stacking corners and wheel plates matter here more than anywhere, because everything travels as one stacked pallet.

Related: artwork and sign transport cases, stand and tripod cases, trade-show trunks.

Road cases for esports and gaming events

Tournament builds move like touring rigs: PCs, monitors, peripherals, comms and a network rack, packed and unpacked in a weekend by rotating crew. Foam-lined Shallow Lid cases for the machines, 50/50 Split for the panels, a rack for the switches.

Related: computer and laptop cases, monitor cases, standard rack cases.

Road cases for DJ and mobile entertainment

Controllers, CDJ pairs, mixers, coffins and the record or laptop case that rides on top. Shallow Lid with 1" soft foam, casters on the bigger builds, side handles on everything.

Related: DJ cases and consoles, keyboard cases, guitar and bass cases.

How custom road case pricing works

The 3D designer does not quote a number. Every design leaves the tool marked "To Be Priced" and a person prices it, because the honest price of a one-off case depends on things a calculator cannot see: how the partitions actually have to be built, whether the foam needs cutting, what the freight class works out to, and how many identical units you need.

What moves the number, roughly in order of impact:

Build the design, click Send My Design, and you get a real quote from a real estimator within one business day. If you would rather talk it through first, contact us or call (631) 562-6323. For fifty or more items overall, start at bulk orders.

About this guide. The information on this page is general guidance to help you plan a build. Measure your equipment and confirm every dimension before ordering: the 3D preview is a visual guide, not a manufacturing drawing, and the specifications written on your quote are the ones we build to. Road Cases USA accepts no responsibility for decisions made from this page alone.