I'm new here. Hello everyone! I'm interested in working with someone to design and make custom musical instrument cases, beginning with saxophones. Is there anyone in the USA who does something like this already? 

Thanks! 

Welcome to the Forum!  I would imagine someone in the USA is making cases of some kind in composite, be it for instruments or other things is anyones guess. I would expect most good composite fabricators could make the composite part of the casing relatively easily.


Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

I have made several instrument cases, along with a number of gun-cases and boxes for sensitive equipment.

I normally just make a plug the  size and shape of the outside of the box I want, then make a mould (usually 2 or 3 part mould)

I use a commercial company that waterjet cuts the foam for the internals, they can cut any shape from 3D files

My usual layup is 2 inside layers of  kevlar/carbon mix and one outside of pure carbon, some customers liked the kvelar mix on the outside as well, so those were made with a "kevlar-carbon-kevlar" layup

The really big cases were made with 4 layers in various mixes of layers two of my own cases have hinges made from EC flexible Epoxy and pure Kevlar weave - 

I have used both infusion and vacuum bagged wet-lay for the boxes 


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