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Lightweight Flight Cases

Custom Flight Cases | A Custom, Lightweight Solution


Lightweight & Strong

With an emphasis on weight, lightweight flight cases as compared to Roadcases are designed for personal travel rather than commercial freight, a great solution for taking your gear with you on the plane, train, car or bus.

Our custom flight cases are made with a lightweight honeycomb composite panel called Flightpanel®, making them extremely rigid and durable, whilst keeping weight to a minimum.


Great for travelling sales/product kits, laptop/IT equipment, music and AV equipment, lightweight flight cases are a great solution for items that need to travel with you regularly and stay protected, we can make custom flight cases to order any shape, size or configuration you require!


With over 10 years in road and custom flight case production, our experienced design and production team can help you find or build a solution that takes care of all your needs.

Our cases are made locally in our Bayswater VIC production facility, with a focus on quality and turnaround times. As an Australian manufacturer we pride our selves on high quality construction and short lead times.

Quality Hardware

We only use the best hardware when building our Flight and Road cases, utilizing a range of Penn Elcom products, we ensure that our build quality, and hardware longevity are second to none, making us your most qualified manufacturer of custom made flight cases in Australia.


With advanced production techniques used as well as in house CNC technology, large runs or complex foam designs aren’t a problem, and dealing direct with the manufacturers means that your budget is well looked after.


Solutions fitted to a budget – Tell us what you need, and where your budget sits, and we can tailor a custom built flight case that specifically meets your needs. We are confident that our expert team can make a custom flight case of any requirement. There is no job too complex for Protectapack.


Standard construction highlights include:

  • HD 10mm Flightpanel® Honeycomb composite panel
  • Heavy duty Aluminium angle covering all corners, hybrid tongue in groove angle on lid openings
  • Recessed lockable Penn Elcom butterfly latches
  • Recessed sprung handles
  • A range of heavy duty wheel options including locking swivel castors and built in corner castors
  • Fully customisable foam interiors, ranging from simple high density foam linings, through to extra padded or CNC cut inserts.
  • 100mm HD Penn Swivel Castor wheels
  • 50mm Mini swivel castors
  • Inbuilt Corner castor options
  • Extendable handle options to use with corner castors
  • Lift out Drop Tray
  • Foam lined dividers
  • Straps/tie down points
  • Stackable castor cups
  • Stackable case feet
  • Overlatches for joining cases in transit
  • Hinged or lift off lid
  • Trapdoors
  • Label holder
Build Formats
  • Top loading style
  • Lift off lid/shallow base
  • 50/50 split
  • Front/rear lids
  • Briefcase style
Foam Options

Lightweight Flight Cases Gallery

By Industry

IT Equipment

A great solution to carrying multiple laptops, tablets and other communications systems, ask us about our custom multiple laptop/tablet cases Also available, lightweight 19”rack cases for servers and switches on the move.

Sales Demo Kits

A great tailored solution to your traveling demo or sales kit, combined with our custom CNC cut foam inserts, a flight weight flight case will offer you a neat, tidy and well presented kit!

Specialist Tool and Equipment Cases

If you travel regularly with a certain set of tools or equipment, a flight case is a great option for making sure your kit arrives safely at the other end!