I've heard good things from trusted sources about Orucase Airport Ninja case.
Just yesterday I just packed up a Ritchey BreakAway in it's case and it's both light and pretty compact. Still a fair amount of disassembly and assembly work. The case is very well made but I don't see how it could work for any other frame aside from BreakAway and maybe S&S coupled ones.
If you are traveling domestically many providers will ship bikes for no additional luggage charge. Even if it's in a bike box, which when packed right is very secure and very cheap.
Josh Z