I've had pieces of the impact deflection ribs break off of several Pelican 1650 cases, and just last weekend had another piece break off an SKB hardcase. I've had a couple of handle breaks, and lost lots of those thin steel padlock reinforcement clips.
Inside, I've suffered several hundred dollars worth of damage to remote switches and brass release levers to various lens mounting accessory components (not the lenses themselves, which are packed separately). All damage occurs presumably following a TSA inspection, where the gear is not repacked as found, but any which way it can be stuffed back in to move on to the next bag.
It is kind of frustrating to arrive on the job with broken parts that worked perfectly when I pretested and packed for the job. Not everything can be carried aboard. This was last week's pack. Over 300 lbs. Most things individually wrapped, in case the case pops open and the contents spills out... which happened in the parking lot last week, with no damage. I've often seen the smaller 1560 case appear on the baggage carousel with one or more latches opened, so I zip tie the cases, and date/time stamp the zipties.
But I haven't been able to find a way to reduce small parts breakage from rough handling/repacking by TSA inspectors. I've never had any problems with lenses or bodies, but the small parts that I assemble for remote triggering and fixturing cameras in places where it is not possible for humans to shoot from sometimes sustain damage. The more "protection" I add to the pack, the more weight I add to the pack, and the fewer parts I can bring along to fixture the cameras in order to make those hard to get shots. Yet if I don't pack the protection, some pieces could get damage, and in the field, I do not have the tooling to fix, nor does any store carry the parts to replace.
I need to refine my pack further to prevent this, even though my pack has gone through many refinements over the last 15 years. I've been reading this thread for ideas, but haven't been able to get through all 6,000 plus posts in one sitting. I finally decided to post about my problems to get feedback, because most of the posts I'm reading are about backpacks, which I don't use. I only travel with hard cases, but need a better way to pack the small items inside those cases.