Kind of an issue of physics. "Light weight" and "hard shell" doesn't really play well together, especially when you are filling it with fairly heavy items. I've found that the light weight 'luggage' grade bags, rather than gear boxes like Pelican style cases, tend to not hold up nearly as well when you fill them with dense items going through baggage handling. When filled with clothes and such they do fine as the load stressing isn't as high due to the low density and having all the mass spread out across the whole case. When you instead fill them with a fairly dense item, and then try tossing them around baggage handling systems, then you wind up with harsher stress gradients in the material which leads to an increase in failure rate.
At this point I'm thinking that rather than bringing stuff like lighting gear along with me with the limited baggage options on an airplane that I will instead just ship anything overly bulky ahead of me through a courier instead. I'll have more sensible options for boxing stuff up, have less stuff to deal with while I'm at the airports themselves, and if something DOES go wrong and something gets destroyed, then the insurance on it will actually cover the cost of the item rather than having to deal with the common airline view of "Well it isn't really our fault and it probably wasn't worth that much anyway."
Canon EOS 7D | EF 28 f/1.8 | EF 85 f/1.8 | EF 70-200 f/4L | EF-S 17-55 | Sigma 150-500
Flickr: Real-Luckless