Dark studio detail of a rugged case interior with measurement callouts

Guide

Case Size and Selection Guide

Interior vs exterior dimensions, usable space, equipment measurement, foam allowance, weight, and travel considerations.

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Overview

Practical guidance

Choosing the correct case is mostly a measurement exercise. This guide walks through the practical steps: measure the equipment, allow for foam, confirm the interior fits, then verify the exterior meets shipping, storage, and travel limits.

Interior vs exterior dimensions

Every hard case has two size sets: exterior (overall footprint) and interior (usable cavity). Match your equipment against the interior. Match your shipping, pallet, vehicle, and airline limits against the exterior.

Measure the equipment first

Record length, width, and height of every item that will travel in the case, including cables, batteries, and accessories. Measure at the widest point — handles, lens hoods, antennas, mounts.

Add foam allowance

Custom foam adds material around each item. Plan for at least 20–25 mm of foam wall between items and between items and case walls. Add 10–15 mm above the tallest item for lid foam compression.

Weight and payload

Confirm loaded weight against handle, wheel, and airline limits. Rack cases, long cases, and coolers can exceed typical airline check-in limits when fully loaded.

Travel and shipping

Airline check-in, hold luggage, courier pallet, and vehicle mounting all have different exterior constraints. Confirm exterior dimensions early to avoid oversized handling fees.

Step by step

How to work through it

1. Inventory the payload
List every item and accessory that must travel in the case.
2. Measure at the widest point
Include handles, mounts, lens hoods, cables, and any protrusions.
3. Add foam allowance
Add ~25 mm around each item and above the tallest item.
4. Compare against interior
Check candidate cases against your padded footprint, not raw equipment size.
5. Confirm exterior limits
Verify against shipping, pallet, vehicle, and airline constraints.

Reference

Common allowances

Consideration	Typical allowance
Foam wall between items	20–25 mm
Foam wall to case interior	20–25 mm
Lid foam above tallest item	10–15 mm
Cable / accessory pocket	Reserve one bay or lid organizer

Allowances vary by equipment fragility, foam density, and layout complexity.