How to Order a Custom Moving Head Flight Case

Moving head lights are among the most valuable and delicate pieces of equipment used in stage productions, concerts, theaters, television studios, and rental companies. A properly designed flight case not only protects the fixtures during transportation but also improves loading efficiency and extends the service life of the equipment.

Unlike standard flight cases, a custom moving head flight case must be designed around the exact dimensions of the lighting fixture. Providing accurate information to the manufacturer is the key to receiving a flight case that fits perfectly.

If you are new to custom flight cases, you may also find How To Custom Produce A Flightcase helpful.

the flight case dimensions fall into 2 parts.

the first part is the outside dimension, and the inside dimensions.

so if you want to have a custom produced flightcase for your equipments or tools, you need to tell the producer 2 groups of data.

for the outside dimensions, it is easy to get into the meaning, and it is easy to comunicate..

also it is for most people to understand.

shown as below.

for the innder side dimensions, it is complicated for new client.

here we would like to tell you what a flightcase factory or producer want to know about the moving head flight case.

1. how many pieces do you want to have in one flightcase.

   normally, we suggest 2 in 1. it means 2 pieces in 1 case. as the picture shown up.

2. we would like to know several datas about the moving head as the picture. if you will provide a draft as the picture, it shall be much helpful.

   (1)base length, width and thinckness

   (2)full height of light

   (3)yolk width and length

   (4)lighting head length and diameters ( front and backside)

   beacause the moving head is shall be up-down insert into the padding foam. you can see in the picutre below.

Why Choose a Custom Flight Case?

Moving head lights are expensive precision devices that contain:

• Optical lenses

• Pan and tilt mechanisms

• Electronic control boards

• Cooling systems

• Display panels

Improper transportation can lead to costly repairs or equipment failure.

A custom flight case minimizes movement during transport while providing excellent shock absorption.

Learn more about the benefits in What Are the Benefits of Using a Flight Case?.

Outside Dimensions vs. Inside Dimensions

When requesting a quotation, manufacturers usually require two groups of dimensions.

Outside Dimensions

Outside dimensions refer to the overall size of the finished flight case.

These dimensions determine:

• Shipping size

• Storage space

• Truck loading

• Warehouse stacking

• Freight cost

Outside dimensions are generally easy for customers to understand.

Inside Dimensions

The inside dimensions are much more important because they determine whether the moving head fixture fits safely inside the case.

These dimensions also define the design of the foam inserts and internal partitions.

Decide How Many Fixtures Each Case Will Hold

One of the first questions a manufacturer will ask is:

How many moving head lights do you want in one flight case?

Common configurations include:

• 1-in-1

• 2-in-1 (most popular)

• 4-in-1

• 6-in-1

A 2-in-1 configuration usually provides a good balance between protection, weight, and transportation efficiency.

Rental companies often choose multiple-fixture cases to reduce loading time.

Dimensions the Manufacturer Needs

To design the foam insert accurately, manufacturers usually require several key measurements.

1. Base Dimensions

Measure:

• Base length

• Base width

• Base thickness

These dimensions determine how the fixture sits inside the foam.

2. Overall Fixture Height

Measure from the bottom of the base to the highest point of the fixture.

This determines the internal depth of the flight case.

3. Yoke Dimensions

The yoke is one of the widest parts of many moving head lights.

Provide:

• Yoke width

• Yoke length

This helps ensure the fixture fits comfortably without unnecessary pressure.

4. Lighting Head Dimensions

Measure the moving head itself.

Include:

• Head length

• Front diameter

• Rear diameter

These measurements are especially important because the head is usually surrounded by protective foam.

Provide Photos or Drawings

Technical drawings greatly improve manufacturing accuracy.

Helpful documents include:

• Product drawings

• CAD files

• PDF dimension sheets

• Manufacturer specification sheets

• Photos from multiple angles

Even simple hand sketches with dimensions are useful.

The more information you provide, the more accurately the foam insert can be designed.

How the Foam Is Designed

Most moving head flight cases use CNC-cut foam inserts.

The fixture is normally stored in an upright position.

The foam supports:

• Base

• Yoke

• Lighting head

Proper foam design prevents vibration while avoiding excessive pressure on sensitive components.

If you would like to learn more about foam selection, read Choose Grid Foam or Pearl Foam for ABS Flight Cases.

Other Information to Provide

Besides dimensions, manufacturers may also ask for:

• Fixture model

• Fixture weight

• Brand

• Quantity required

• Transportation method

• Preferred case material

• Logo printing requirements

• Wheel requirements

• Hardware preferences

Providing complete information reduces design revisions and speeds up production.

How to Measure Correctly

Incorrect measurements are one of the most common reasons for redesign.

Before submitting dimensions:

• Measure the widest point.

• Include handles and connectors.

• Measure the fixture in its transport position.

• Double-check all measurements.

• Confirm whether accessories are stored inside the case.

For a complete measuring guide, see How Do I Measure My Equipment to Ensure the Right Flight Case Size?.

Frequently Asked Questions

Can I send only the product model?

Sometimes yes.

If the manufacturer already has production drawings for your lighting fixture, the model number may be sufficient.

Otherwise, dimensions or technical drawings are still recommended.

Can one flight case hold different lighting models?

Generally, this is not recommended because different fixtures require different foam layouts.

What is the most popular configuration?

A 2-in-1 moving head flight case is the most commonly used configuration because it balances protection, handling, and transportation costs.

Can accessories be stored inside the case?

Yes. Many custom flight cases include additional compartments for power cables, clamps, safety wires, and manuals.

Conclusion

A custom moving head flight case provides the highest level of protection for valuable stage lighting equipment. By supplying accurate dimensions, fixture information, and reference drawings, you help the manufacturer design a case that offers excellent protection, efficient transportation, and long-term durability.

Before placing your order, make sure you understand the required measurements, foam layout, and transportation needs. A properly designed custom flight case is an investment that protects your equipment and reduces maintenance costs over many years of professional use.

For further reading, you may also find these guides useful:

• How To Custom Produce A Flightcase

• How Do I Choose the Right Flight Case for My Needs?

• How Do I Measure My Equipment to Ensure the Right Flight Case Size?

• What Type of Material Is Used in the Construction of Flight Cases?