What Are Road Cases Made Of?
Road cases from Calzone & Anvil Case Co. are made from high-strength, impact-resistant materials designed for maximum protection and durability. Every case is engineered with precision-crafted components to meet the demands of touring professionals, AV technicians, and industrial applications.
These materials are chosen for their ruggedness and for how well they protect valuable equipment in motion. From laminated plywood to precision-milled extrusions and shock-absorbing foam, each component works together to form a case that is strong, smart, and field-ready.
Core Materials Used in Calzone & Anvil Road Cases
The materials used in a road case determine how well it holds up under pressure, both literally and figuratively. Below are the five primary material systems that define every case we manufacture.
1. Laminated Plywood Panels for Strength and Durability
This is the structural core of most road cases. We use premium birch plywood for its exceptional strength-to-weight ratio. The wood is then laminated with ABS plastic or fiberglass, which adds exterior toughness, increases resistance to scratches, and provides a clean, professional finish. Hammered aluminum exterior options are also available for added durability and visual appeal.
The panel thickness depends on the protection required. Options range from ¼ inch for lighter loads to ¾ inch for extremely heavy or delicate equipment. Each thickness serves a specific purpose. Thinner builds are lighter and more portable. Thicker panels absorb more shock and offer greater surface protection, especially for long-haul touring or industrial applications.
Laminated plywood forms the outer walls, floor, and lid panels of our cases. It is bonded securely with industrial adhesives and fastened with riveted aluminum edging. This gives each panel the resilience to handle repeated drops, strikes, and pressure over time.
2. Reinforced Aluminum Extrusions for Structural Strength
Plywood needs framing. That is where our custom-milled aluminum extrusions come in. These run along every exterior edge, corner, and lid-to-body seam. They provide rigidity, alignment, and structural strength without excessive weight.
The design of our aluminum extrusions is proprietary. They feature tongue-and-groove interlocking systems that seal lids tightly, align base and lid panels precisely, and resist twisting. These extrusions are essential to creating a fully enclosed and self-reinforcing case body.
Stacking corner options can also be installed as part of this system. They allow multiple cases to stack securely without slipping or shifting, which is critical in tour trucks, warehouses, or hospital storage rooms. These brackets also reduce wear and stress on corners over time.
We use these extrusions across most case types, from touring racks and Roll-in-Ramp cases to TV monitor cases and display enclosures. The result is a frame that stays square, holds fast, and travels well.
3. Shock-Absorbing Custom Foam Interiors
A solid shell is only half the equation. Inside the case, shock-absorbing foam plays a crucial role in protecting the actual equipment. We use a combination of EVA (ethylene-vinyl acetate) and PE (polyethylene) foams chosen for their compression resistance and vibration dampening.
Each insert is precision-cut using CAD software, CNC routing, laser-cutting waterjet, or hand tools to match the exact contours of the equipment it protects. These inserts hold equipment firmly in place, preventing side-to-side movement, toppling, or surface damage.
We install foam interiors in most types of cases we build. In monitor cases, foam prevents impact damage to fragile screens. In medical instrument cases, it supports surgical and diagnostic tools. For electronics cases, it keeps servers, amplifiers, or power modules tightly cradled, even during air freight or road travel.
Multi-layered foam systems are often used to separate parts or include accessory compartments. In high-value applications, we design floating foam platforms that add an extra layer of vibration isolation.
4. Industrial-Grade Steel Hardware and Hinges
Hardware defines usability. We use industrial-grade recessed latches, ball corners, and continuous piano hinges in most road cases we build. These are engineered and tested to handle constant motion, sudden impacts, and high operational frequency.
Zinc-coated steel rivets are used to reinforce key mechanical joints. These rivets offer high shear strength, long-term durability, and protection against corrosion. Most latches are countersunk into the panel surface to avoid accidental openings or damage in transit.
Cases may also include butterfly latches for tighter seals, recessed padlock hasps for added security, and steel corner balls to absorb corner strikes. Hardware selection depends on case use; heavier gear requires more anchor points and higher load ratings.
Inside the case, hinges provide long-term alignment and strength at pivot points. Our hinges are secured through both panel and extrusion material, offering maximum pull-out resistance and case alignment over time.
5. Heavy-Duty Casters and Roll-in-Ramp System
Mobility is critical when equipment gets heavy. Many of our builds include polyurethane and steel swivel casters. These casters are rated for heavy loads and provide smooth rolling on concrete, carpet, and uneven ground.
We offer various caster types, such as swivel, fixed, locking, shock-absorbing, and self-centering automatic aligning. They are installed on reinforced caster boards built into the base of the case. This distributes the load evenly and protects the frame from deformation under weight.
One standout system is our Roll-in-Ramp case design. These road cases feature a built-in folding ramp secured with internal brackets and support beams. The surface includes a non-slip coating, and the ramp locks in place during transit. This system is ideal for loading wheeled gear, such as medical carts, AV racks, or mobile diagnostic systems.
Additional features may include forklift skids, dolly plates, and removable trays. These are designed to improve efficiency and protect both the gear and the people moving it.
Why Choose Calzone & Anvil for Your Road Cases
At Calzone & Anvil Case Co., we build road cases to protect what matters most. For more than seven decades, we have supplied custom protective solutions to musicians, AV professionals, broadcast teams, medical transporters, and field technicians.
We do not use generic components. Every material is selected for its performance in real-world environments. Our laminated plywood panels, precision-milled extrusions, custom-cut foam, steel hardware, and mobile support systems are engineered to meet the exact demands of your gear.
Whether you are moving stage equipment, diagnostic instruments, or production displays, we design around your workflow. Our builds are trusted because they do not fail when it counts.
Get in touch today to explore how our road cases can protect your gear, reduce risk, and keep your operation running without interruption.
Explore Calzone & Anvil's Road Cases
- Browse Road Cases -- Explore our touring-ready builds.
- Custom Road Cases -- Learn more about our work with instrument transport and performance cases.
- Monitor Cases -- Discover our impact-resistant cases for screens, displays, and media systems.
- Ramp Cases - Check out our Roll-in-Ramp cases.
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