It was recently suggested to me that NPU should sponsor a competition to design a travel case for the uilleann pipes. I thought this was a great idea.
I broke down my 3/4 set into my backpack a few years ago and got the thing on Ryan Air. Not sure if that would work now…
Guess I’m the lucky one here, flew out from Detroit to San Diego for Christmas 2 years ago. Have my pipes in a break down shotgun case 13X36 in, (I know, just asking for problems). Standing in line for security, guard kept glancing down at the case and then at me. Finally, he had to say something…“Please tell me you don’t have a shotgun in there sir!”, I responded, “No sir, I’m a musician.”. He actually managed a smile. Put it on the conveyor for xray, waited and waited on the other end while they examined the image. The operator called out for a second opinion and I’m thinking, okay, here we go. Finally, the guard at the end of the conveyor says, “what do you have in there?” I told him and he called out, “It’s bagpipes, see I told you so!” The case BTW fits perfect in the overhead being only 4 inches deep, carry ons lay right on top. I think my relatives in San Diego wished they would have seized them! 
I just retrofitted a Gator hard sided fiddle case for my 3/4 set, works perfectly:
http://www.amazon.com/Gator-GC-VIOLIN-Deluxe-Full-Size-Violin/dp/B000VM3NMO
That looks like it would make an excellent pipe case.
No doubt that it is a drag the violinist got her instrument damaged. I find it strange that a professional such as herself, would not have insured the instrument!?
This sort of threat has been coming up for many years. My solution was to have a soft case made within the parameters of what most airlines allow. Gay’s idea, although it sounds like a total pain in the hole to put back together, seems to be right on the money. I believe nearly 10 years ago it was the former editor of the Piper’s Review, Wally Charm who did much the same thing when he traveled. (*I’m pretty sure it was him, at very least).
Part of the issue is that airlines charge for checked baggage now, so everyone is carrying more on. My experience is that once the overhead bins get full the airline positions someone at the door of the plane to take the carry-on items of the last people boarding. They take your carry-on and put it under the plane. I have never had a problem once I tell them I have a musical instrument, as they have always found a place on the plane to store it, but it is something to consider. The smaller you pack the easier it will be to keep your instrument with you on the flight.
I"ve flown quite a bit with Highland pipes, from California to the Eastern US and over to Scotland, and I’ve had no troubles. I usually break the pipes down and put them into my ordinary rolling suitcase. Pipes, kilt, and everything in the one case, which fits into the overhead.
I’ve also got a cloth-over-rigid-foam pipe case that meets the airline dimensions and sometimes I carry on the pipes in that, and check the rolling suitcase.
One worry no one has mentioned is that pipes with real ivory on them are subject to seizure by Customs when you enter a different country.
Our Pipe Band has flown to the UK many times, with nearly every piper having ivory-mounted pipes, with no issues. But it supposedly has happened that pipes have been confiscated. You’re supposed to have papers with your pipes certifying that the ivory is pre-ban ivory.
When I flew to Japan with my uilleann full set I had them in a sturdy aluminum case and I checked them, with no problems.