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Flight Cases - Protect your equipment on the road with custom built flight cases.

Looking for the ultimate protection to eliminate transit damage? Build a bespoke flight case for your products and your business requirements.

By using a custom built flight case, you can be confident that your equipment is safe and secure. Providing ultimate protection for your equipment in transit within a strong and durable custom flight case. So whether you are looking for a flight case on wheels, a custom aluminium flight case, or a light weight polypropylene panel flight case we can help.

Made to order Flight Cases

Whether you need an empty, foam lined or flight case complete with custom cut foam insert or internal dividers, PottertonPacs are a single stop custom flight case and foam supplier with an extensive range of designs and fittings.  


Advantages of made to order flight cases:

  • Custom designed and built to suit your suit your equipment
  • Option to incorporate company colours 
  • Logo or branding options include digital print, silk screen printing & engraving
  • Superior UK-manufactured quality
  • Unique and personalised appearance
  • You can house your product samples or equipment with internal dividers and foam inserts designed and cut to fit each item exactly
  • Bulk order discounts


Get in touch today to take advantage of our free quotation and advice service on our bespoke flight cases.

Learn more about Flight Cases

How can you customise your flight case?

How CAD designs create amazing flight cases

FAQs About Flight Cases

What information do you require to supply a quotation for flight cases?

To enable us to supply you with a quote for a custom flight case, please let us know the size(s) of the item(s) that will be housed within the case. We usually work from the product size and add additional allowances to these dimensions to allow for easy loading and unloading.

Please also supply any of the following:
– overall dimensions supplied via email
– a physical set of samples
– a rough hand sketch with the dimensions and depths for each item if more than one
– a photograph with a perimeter size and depth
– a digital drawing, preferred formats are DXF, DWG, PDF or Jpeg

Along with any of the above, please supply the approx. weights for the item/items.

If you have any specific requirements such as design, preferred colour, branding requirement and required by date (if any of these apply), please ensure you also include these details as well as the quantity required.

Lastly, if delivery will be required for the goods then please also provide the postcode or full delivery address.

What is the minimum order for a custom made flight case?

We will supply 1 off’s, however, as volumes increase, quantity/production discounts come into effect, so bulk orders are more cost effective.

Can I have a flight case on wheels?

Yes, absolutely. Smaller flight cases can be fitted with telescopic handle and towing/corner wheels, and larger flight cases or cases that are to hold heavy items would be fitted with castors. Castors are also available with brakes to prevent unwanted movement occurring in transit.

If you are unsure whether you would require corner wheels or castors, we can certainly recommend the design most suitable for your specific requirements. Please feel free to contact us directly to discuss your requirements in more detail.

What materials are flight cases made from?

Our standard material unless otherwise requested is 7, 9, 12 or 15mm black hexaboard.

The thickness for each order is elected by us dependant on the size of the case and the weight of the item to be carried or transported within the case.

What colour options are available for custom made flight cases?

All our bespoke flight cases are constructed in black hexaboard unless otherwise requested. Alternative panel insert materials offer a broad variety of colour options which included black, white, grey, blue, red, green, orange, yellow, purple and pink.

Subject to availability (and in some case minimum order quantity) panel colours can be colour matched to specific colours and the frames of the flight cases can even be powder coated.

Can flight cases be locked for additional security?

Yes, they can. Padlock lugs can be added to flight cases to enable a padlock to be fitted, if required for additional security.

Can I add my logo to a custom manufactured flight case?

Yes, branding or a logo can be added to our flight cases. Options of these include a badge or name plate, CNC routing into the surface of the hexaboard panels or Silk Screen or Digital Print.

Each of these branding options have parameters that have to be worked within, so if you require branding, please get in touch via telephone to find out more information on the options available to suit your flight case enquiry.

Can I have a lightweight flight case?

Yes, you can. For a lightweight alternative, but with the same strength and level of protection, flight cases can be built in lightweight astroboard.

The same aluminium frame and fittings are used in the construction of all of our flight cases. However, by swapping the panel material (which creates the front, back, side, base and lid for this honeycomb sandwich construction polypropylene material), you can reduce the panel weight by 40% of an equivalent case built in hexaboard or laminated plywood.

These lightweight flight cases are available in 4 colours options, which are black, grey, red or blue.

Can I have internal dividers to create different compartments with a flight case?

Yes, it is possible to have dividers within a flight case to create compartments. Dividers can be fixed or movable and can even be foam lined within each compartment to suit your requirements.

What foam inserts options are available for flight cases?

Flight cases can simply be foam lined or a complete custom cut foam interior can be produced to suit your needs exactly.